Rapidly Fabricated Microneedle Arrays Using Magnetorheological Drawing Lithography for Transdermal Drug Delivery

Microneedle arrays (MAs) are among the most promising transdermal drug delivery systems in the last decades due to its minimally invasive nature, convenient operation, and first-pass-metabolism avoidance. However, most MA fabrication methods are difficult to operate, need multiple steps, or require expensive equipment. A novel magnetorheological drawing lithography approach was proposed to rapidly fabricate a flexible microneedle array (FMA) for transdermal drug delivery. A 3D structural liquid MA was drawn in one step from the droplets of curable magnetorheological fluid and maintained its shape under an external magnetic field. The liquid MA was subsequently solidified and sputter-coated with the Ti/Au film to fabricate FMA. FMA morphology, mechanical properties, and transdermal drug delivery performance in vitro were experimentally investigated. FMA consisted of a 5 × 5 cone-shaped microneedle array on a PET flexible substrate. FMA exhibited good strength and excellent penetration performance. It could easily penetrate into skin without breakage, creating microchannels for the promotion of skin permeability. Drugs could be well permeated and diffused in the skin along the microchannels created by FMA. Finally, a dissolvable microneedle array (DMA) was also fabricated by a micromolding technique using FMA as a master template. The DMA exhibited good dissolvable and permeable performance in the agarose block.