A Critical Review of Advances and Challenges in Microinjection Moulding of Polymeric Microneedles

Article

Azarikhah (Student), P., Mushtaq, A., Saifullah, K.M., Prewett, P., Davies, G. and Faraji Rad, Z.. 2025. "A Critical Review of Advances and Challenges in Microinjection Moulding of Polymeric Microneedles." Journal of Drug Delivery Science and Technology. https://doi.org/10.1016/j.jddst.2025.107435
Article Title

A Critical Review of Advances and Challenges in Microinjection Moulding of Polymeric Microneedles

ERA Journal ID14795
Article CategoryArticle
AuthorsAzarikhah (Student), P., Mushtaq, A., Saifullah, K.M., Prewett, P., Davies, G. and Faraji Rad, Z.
Journal TitleJournal of Drug Delivery Science and Technology
Year2025
ISSN1157-1489
1773-2247
Digital Object Identifier (DOI)https://doi.org/10.1016/j.jddst.2025.107435
Web Address (URL)https://www.sciencedirect.com/science/article/pii/S177322472500838X
Abstract

Microneedles are an innovative alternative to hypodermic needles for delivering vaccines and therapeutic agents and sampling biofluids for point-of-care diagnostics. Two key advantages of microneedle patches over hypodermic needles are their painless application and ease of use without requiring skilled personnel. Polymers stand out as an ideal material for the mass production of microneedles, offering a combination of low cost, good mechanical properties, biocompatibility, biodegradability, and high chemical stability. Among different polymer fabrication techniques, microinjection moulding is a well-established industrial process with high potential to address the challenge of mass-producing microneedle devices cost-effectively and efficiently. Despite the significant potential of the technique, research in this area is limited. This article comprehensively reviews the recent advancement in the fabrication of polymeric microneedles via microinjection moulding. It covers injection moulding steps, mould fabrication, and quality assessment of the final product, with a focus on the challenges associated with the mass manufacturing of microneedles. The article investigates the laser micromachining process and its challenges in fabricating negative metal moulds for microneedles, elaborating on the critical role of mould manufacturing in precisely shaping mould-injected microneedles. The physical and rheological properties of thermoplastic polymers that affect the quality of mould-injected microneedles are also reviewed. Finally, opportunities and future directions for advancing research in this field are discussed.

KeywordsMicroneedles; Thermoplastic polymers; Microinjection moulding; Negative metal mould; Laser micromachining
Contains Sensitive ContentDoes not contain sensitive content
ANZSRC Field of Research 2020401705. Microelectromechanical systems (MEMS)
401799. Mechanical engineering not elsewhere classified
401707. Solid mechanics
400303. Biomechanical engineering
400308. Medical devices
401405. Machine tools
401408. Manufacturing processes and technologies (excl. textiles)
401410. Microtechnology
Byline AffiliationsSchool of Engineering
Academic Registrar's Office
Institute for Advanced Engineering and Space Sciences
Centre for Future Materials
Centre for Crop Health (Research)
Centre for Crop Health (Operations)
Institute for Advanced Engineering and Space Sciences (Operations)
University of Birmingham, United Kingdom
University of New South Wales
Centre for Crop Health
Centre for Future Materials (Research)
University of the Sunshine Coast
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