Abstract: A method is provided for forming at least one curved polymeric microneedle, wherein the microneedle includes a base portion and an elongated body portion terminating in a sharp tip, said elongated body portion comprising a lower portion that is 15% to 25% of the height of the microneedle, said elongated body portion being connected to said base layer. The method comprises: heating an array comprising said base layer and at least a segment of said elongated body portion; passing the heated array against a fixed member to bend the microneedles; and allowing the bent, heated array to be cooled. The heat applied to the base layer and elongated body portion is sufficient to cause the heated microneedle to be at or above the glass transition temperature of the polymer of the microneedle, but below a temperature that would cause the lower portion to bend during the passing step.