Abstract: A method for manufacturing microneedle devices and systems and tools for implementing same. The method can include manufacturing a replica mold and forming a microneedle array via the replica mold. The replica mold can be manufactured by disposing replica mold material on a master mold and curing the replica mold material. To reduce manufacturing time, the replica mold material preferably is cured at a high temperature for a relatively short time and then cooled quickly before removal from the master mold. The microneedle array can be formed by disposing microneedle material on the replica mold under vacuum and drying the microneedle material in single or successive disposing and drying operations. One or more optional backing layers can be added to the microneedle array when forming the microneedle device. Advantageously, the disclosed methods, systems and tools can be used to manufacture skin-applied patches for delivering cosmetic and therapeutic agents.

Abstract: A method for manufacturing microneedle devices and systems and tools for implementing same. The method can include manufacturing a replica mold and forming a microneedle array via the replica mold. The replica mold can be manufactured by disposing replica mold material on a master mold and curing the replica mold material. To reduce manufacturing time, the replica mold material preferably is cured at a high temperature for a relatively short time and then cooled quickly before removal from the master mold. The microneedle array can be formed by disposing microneedle material on the replica mold under vacuum and drying the microneedle material in single or successive disposing and drying operations. One or more optional backing layers can be added to the microneedle array when forming the microneedle device. Advantageously, the disclosed methods, systems and tools can be used to manufacture skin-applied patches for delivering cosmetic and therapeutic agents.

Abstract: A method for manufacturing microneedle devices and systems and tools for implementing same. The method can include manufacturing a replica mold and forming a microneedle array via the replica mold. The replica mold can be manufactured by disposing replica mold material on a master mold and curing the replica mold material. To reduce manufacturing time, the replica mold material preferably is cured at a high temperature for a relatively short time and then cooled quickly before removal from the master mold. The microneedle array can be formed by disposing microneedle material on the replica mold under vacuum and drying the microneedle material in single or successive disposing and drying operations. One or more optional backing layers can be added to the microneedle array when forming the microneedle device. Advantageously, the disclosed methods, systems and tools can be used to manufacture skin-applied patches for delivering cosmetic and therapeutic agents.

Abstract: A microneedle device suitable for application to the skin and methods for using the same. The microneedles are made of one or more biocompatible polymers that optionally provide a cosmetic benefit when dissolved within the skin. Optionally, the microneedles also may be used to deliver other active ingredients to the skin. The device is characterized by a microneedle layer, an intermediate layer of a liquid-soluble polymer, and an outer, liquid-permeable layer that is in fluid communication with the intermediate layer. In use, the device is applied to the skin such that the microneedles penetrate the skin surface. A liquid (e.g., water) is applied to the outer layer, causing dissolution of the intermediate layer, thereby detaching the microneedles within the skin from the device body. The remainder of the device is then removed and discarded.