Fabrication of polymer microneedle array based on tungsten mold and optimized replication method

Fabrication of high performance tungsten microneedle array (MNA) which has tunable height and diameter is reported for the first time. Further, stable replication of cycloolefine copolymer (COC) MNA is achieved using novel vacuum isostatic hot embossing followed by PDMS casting with tungsten MNA mold. Radius of needlepoint is less than 1pm while microneedle height reaches as high as 100μm. High hardness of tungsten ensures reliability of mold which offers commercial potential for this method.