Fabrication of photomasks consisting microlenses for the production of polymeric microneedle array

A photomask consisting plano-convex microlenses for the production of polymeric microneedles was fabricated from a microinjection array. The microinjection array was first fabricated using photolithographical approach and subsequently assembled onto a polydimethylsiloxane (PDMS) stamp. Poly (ethylene glycol) diacrylate (PEGDA) solution was loaded into the microinjection stamp. The microinjection stamp was then applied onto a coverslip to dispense the polymer solution, producing liquid microdroplets. They were then irradiated to form plano-convex microlenses. These microlenses were evaluated for their geometric properties and were fabricated into photomasks. The photomask consisting microlenses was used to fabricate polymeric microneedles that were evaluated and tested for skin penetration efficiency.