Determination of vat-photopolymerization parameters for microneedles fabrication and characterization of HPMC/PVP K90 dissolving microneedles utilizing 3D-printed mold

Three-dimensional (3D) printing serves as an alternative method for fabricating microneedle (MN) patches with a high object resolution. In this investigation, four distinct needle shapes: pyramid mounted over a long cube (shape A), cone mounted over a cylinder (shape B), pyramidal shape (shape C), and conical shape (shape D) were designed using computer-aided design (CAD) software with compensated bases of 350, 450 and 550 µm. Polylactic acid (PLA) biophotopolymer resin from eSun and stereolithography (SLA) 3D printer from Anycubic technology were used to print MN patches. The 3D-printed MN patches were employed to construct MN molds, and those molds were used to produce hydroxypropyl methylcellulose (HPMC) and polyvinyl pyrrolidone (PVP) K90 dissolving microneedles (DMNs). Various printing parameters, such as curing time, printing angle, and anti-aliasing (AA), were varied to evaluate suitable printing conditions for each shape. Furthermore, physical appearance, mechanical property, and skin insertion ability of HPMC/PVP K90 DMNs were examined. The results showed that for shape A and C, the suitable curing time and printing angle were 1.5 s and 30° while for shapes B and D, they were 2.0 s and 45°, respectively. All four shapes required AA to eliminate their stair-stepped edges. Additionally, it was demonstrated that all twelve designs of 3D-printed MN patches could be employed for fabricating MN molds. HPMC/PVP K90 DMNs with the needles of shape A and B exhibited better physicochemical properties compared to those of shape C and D. Particularly, both sample 9 and 10 displayed sharp needle without bent tips, coupled with minimal height reduction (< 10%) and a high percentage of blue dots (approximately 100%). As a result, 3D printing can be utilized to custom construct 3D-printed MN patches for producing MN molds, and HPMC/PVP K90 DMNs manufactured by those molds showed excellent physicochemical properties.