Microneedle Array Mold Design
We developed a 100-needle microneedle mold system for repeatable production of hydrogel microneedle arrays. Beyond CAD modeling, the design incorporated DFM, demolding strategy, draft angles, base fillets, feature spacing, and dimensional control to reduce damage during release and improve repeatability. The parametric architecture also allows key dimensions and array geometry to be adapted for different applications and production requirements.
Parametric microneedle master and negative mold geometry developed for repeatable soft-lithography fabrication. The design supports rapid iteration of needle spacing, dimensions, and array size.
Proposed manufacturing workflow from SLA-printed positive template to polymer negative mold and batch production of hydrogel microneedle patches. The process was designed around low-cost, repeatable fabrication.
Mold geometry incorporated draft, filleted needle bases, and controlled feature dimensions to improve demolding and reduce hydrogel damage. The parametric model allows key dimensions to be adjusted for different applications.
Concept visualization showing the compact scale of the finished microneedle patch relative to the reusable casting mold. The approach was intended to support economical production of repeatable test batches.