Fabrication, Simulation, and Mechanical Characterization of Curcumin-Loaded PVA/PVP Microneedle Arrays Using Custom...

Microneedle (MN) arrays offer a novel and minimally invasive platform for transdermal drug delivery. This study presents an approach for the design and fabrication of MN array models for biomedical applications using custom 3D-printed micro-molds. Material analysis of the polyvinyl alcohol (PVA) and polyvinylpyrrolidone (PVP) matrix in a 3:1 weight ratio was conducted under varying geometric configurations, curcumin (CUR) dosages, and target penetration depths of 300 to 500 μm. Computational simulation using computer-aided design (CAD) and finite element analysis (FEA) on ANSYS (Canonsburg, PN, USA) measured for total deformation, stress distribution, insertion pressure, and factor of safety. Elimination criteria were applied, narrowing down to specific models that were experimentally validated through material formulation, micro-molding, and material characterization. The selected MN models were analyzed by insertion and penetration efficiency testing on porcine skin. The results showed that higher CUR concentrations reduced mechanical strength and Young's modulus, while mid-range dosages (2-6 mg) combined with optimized geometric spacing produced MNs with maintained structural integrity and effective performance. Conical microneedles demonstrated the most favorable balance of mechanical stability, controlled swelling behavior, and high insertion efficiency. The study recommends this approach as a feasible and reproducible method for localized wound-healing applications.