Executive Summary : | Transdermal drug delivery through the skin is limited by traditional methods due to inflammation and pain. Microneedles, tiny projections arranged in arrays, are used to create microchannels in the skin without reaching the nerve. These microneedle arrays offer pain-free drug delivery, self-administration, infection reduction, and ease of waste disposal. Biocompatible and biodegradable polymer and hydrogel-based microneedles have gained popularity due to their higher drug delivery efficiency and cost-effectiveness. Micromolding techniques are used for upscale fabrication of polymeric microneedles, involving the master mold template to produce elastomer PDSM female molds. High-strength materials like stainless steel, Ti, and Ni alloys are needed for the master mold template. Microfabrication methods like photolithography and dry/wet etching are not suitable for mass production due to material limitations and expensive equipment and clean room facilities. The micromillig process can be a promising approach for creating high-strength materials with high aspect ratio features. However, dynamic instabilities may introduce tool failure and mold breakage due to lower flexural stiffness. High rotational speeds can counter this limitation. There is a need to develop a fabrication system for scalable manufacturing of polymeric microneedle arrays with high aspect ratio geometries with low-cost cleanroom-free fabrication. Experimental characterization of the fabricated master mold of high-strength materials will be performed at different process parameters. A fully autonomous fabrication system will be developed to address scientific and technological challenges in microfabrication processes. This work aims to identify optimized parameters for manufacturing high-strength materials, enhancing the life of the mold and product quality, and improving the sustainability of the process. |