Cleanroom-compatible polymeric nanostructured microneedle patch for advanced wearable applications

Microneedles are revolutionizing healthcare by enabling minimally invasive drug delivery and real-time biosensing. This study presents an innovative polymer-based wearable system that integrates SU-8 microneedle arrays with a flexible, stretchable substrate, ensuring close skin conformity. Using a single-step backside lithography technique, we fabricated 3D microneedles, followed by a simplified etching process to produce nanostructured surfaces that enhance sensing functionality. The patch supports metal and dielectric deposition, enabling versatile sensing configurations. As a proof of concept, the device demonstrated reproducible performance for hydrogen peroxide electrochemical sensing. Tests on a skin mimic model confirmed its ability to penetrate successfully, as predicted by simulations. This scalable, cleanroom-compatible technology represents a significant advancement in microneedle-based diagnostics, paving the way for practical and minimally invasive healthcare solutions.