Microneedle arrays (MNs) have been extensively studied for transdermal drug delivery due to their straightforward administration and ability to deliver a wide range of therapeutics. However, current fabrication methods hinder throughput and customizability, and the scope of viable materials is limited. Additive manufacturing (3D printing) of microneedle arrays allows for high control over resolution, reproducibility, manufacturing speed, and part customization. Furthermore, poly(propylene fumarate) (PPF) is a synthetic, bioresorbable polymer that has been used previously for 3D-printed biomedical applications. In this work, PPF-based microneedle arrays were fabricated via Continuous Liquid Interface Production (CLIP), which enabled facile part manufacturing and customization of microneedle size and geometry. Thiol-ene click chemistry yielded crosslinked polymeric materials during the photochemical printing process, resulting in a unique window of tunable mechanical and degradation properties. These 3D-printed MNs successfully penetrated porcine skin <i>ex vivo</i> and demonstrated controlled release of a model drug surrogate <i>in vitro</i>.

Photochemical 3D printing of bioresorbable microneedle arrays for controlled transdermal drug delivery

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