Free-Form Microfluidic Microneedle Array Patches

Personalized biomedical devices, such as microneedle array patches (MAPs), offer a promising transdermal drug delivery technology, providing a safe, painless, and self- administered alternative to traditional hypodermic injections. Despite their potential for precise therapeutic release, MAP adoption has been limited by challenges in payload capacity, treatment versatility, and manufacturing scalability. To address these issues, we integrated microfluidic channel designs with MAP technology, enhancing its functionality for delivering a range of payloads, from liquid therapeutics to solid-state cargos, at tunable volumes. Using injection continuous liquid interface production (iCLIP), a novel additive manufacturing approach, we fabricated high-resolution microfluidic MAPs with complex designs. Inspired by the stingers and fangs of various venomous animals, we developed a biomimetic microneedle design that prevents clogging, enhances mechanical strength, and eliminates needle leakage, thereby improving therapeutic delivery efficiency. Our technology reliably delivers multiple distinct payloads, enables combinational mixing, and enables point-of-care reconstitution of solid-state payloads.