High-throughput manufacturing of transdermal microneedle arrays poses a significant challenge due to the high precision and number of features that need to be produced and the requirement of multi-step processing methods for achieving challenging micro-features. To address this challenge, we report a flexible and cost-effective process chain for transdermal microneedle array manufacture that includes mould production using laser machining and replication of thermoplastic microneedles via micro-injection moulding (micromoulding). The process chain also incorporates an in-line manufacturing data monitoring capability where the variability in the quality of microneedle arrays can be determined in a production run using captured data. Optical imaging and machine vision technologies are also implemented to create a quality inspection system that allows rapid evaluation of key quality indicators. The work presents the capability of laser machining as a cost-effective method for making microneedle moulds and micro-injection moulding of thermoplastic microneedle arrays as a highly-suitable manufacturing technique for large-scale production with low marginal cost.

透皮微针阵列的高通量制造提出了巨大的挑战，这是由于需要生产的高精度和许多特征，以及需要多步加工方法来实现具有挑战性的微特征。为了解决这一挑战，我们报告了一种用于透皮微针阵列制造的灵活且具有成本效益的工艺链，包括使用激光加工的模具生产以及通过微注射成型（微模）复制热塑性微针。该工艺链还具有在线制造数据监视功能，其中可以使用捕获的数据在生产运行中确定微针阵列质量的变化。还采用了光学成像和机器视觉技术来创建质量检查系统，从而可以快速评估关键质量指标。这项工作展示了激光加工作为制造微针模具的经济有效方法的能力，以及热塑性塑料微针阵列的微注射成型的能力，这是一种以较低的边际成本进行大规模生产的高度适合的制造技术。