System and Method for Making Microneedles

Abstract

Systems and methods for creating microneedle arrays capable of delivering a suitable drug dosages to subjects are provided. In one aspect, a method comprises creating at least one forming mold using laser ablation in a cross-over line pattern. The method further comprises casting a first material onto the at least one forming mold to create at least one microneedle mold. The method further comprises casting a second material onto the at least one microneedle mold to create at least one hollow microneedle.

1 - 20 . (canceled) 
     
     
         21 . A microneedle patch comprising:
 a plurality of microneedles, each of which includes a base and a tip, at least the tip including a macroporous structured material adapted to host a drug within pores of the macroporous structured material; and   a substrate for supporting the plurality of microneedles at the base of each microneedle.   
     
     
         22 . The microneedle patch of  claim 21 , wherein the macroporous structured material includes a cured biocompatible resin. 
     
     
         23 . The microneedle patch of  claim 21 , wherein the macroporous structured material includes a homogenous composite. 
     
     
         24 . The microneedle patch of  claim 21 , wherein the macroporous structured material includes a sufficient hardness for human dermal penetration. 
     
     
         25 . The microneedle patch of  claim 21 , wherein the substrate is flexible and adapted to conform to a non-flat surface. 
     
     
         26 . The microneedle patch of  claim 21 , wherein macroporous structured material includes the drug within the pores of the macroporous structured material. 
     
     
         27 . The microneedle patch of  claim 26 , wherein the drug is a part of a concentrated solution. 
     
     
         28 . The microneedle patch of  claim 26 , wherein the drug is a part of a powder. 
     
     
         29 . A microneedle patch comprising:
 a plurality of microneedles, each of which includes a macroporous structured material and a drug within pores of the macroporous structured material; and   a substrate for supporting the plurality of microneedles for common application of the plurality of microneedles into a receiving surface.   
     
     
         30 . The microneedle patch of  claim 29 , wherein the macroporous structured material includes a cured biocompatible resin. 
     
     
         31 . The microneedle patch of  claim 29 , wherein the macroporous structured material includes a homogenous composite. 
     
     
         32 . The microneedle patch of  claim 29 , wherein the substrate is flexible and adapted to conform to a non-flat surface. 
     
     
         33 . The microneedle patch of  claim 29 , wherein the drug is a part of a concentrated solution. 
     
     
         34 . The microneedle patch of  claim 29 , wherein the drug is a part of a powder. 
     
     
         35 . A microneedle patch comprising:
 a plurality of microneedles, each of which includes a base and a tip, at least the tip including a macroporous structured hard material with a sufficient hardness for human dermal penetration; and   a flexible substrate for supporting the plurality of microneedles at the base of each microneedle, said flexible substrate being adapted to conform to a non-flat surface.   
     
     
         36 . The microneedle patch of  claim 35 , wherein the macroporous structured material includes a cured biocompatible resin. 
     
     
         37 . The microneedle patch of  claim 35 , wherein the macroporous structured material includes a homogenous composite. 
     
     
         38 . The microneedle patch of  claim 35 , wherein the macroporous structured material includes a drug within pores of the macroporous structured material. 
     
     
         39 . The microneedle patch of  claim 38 , wherein the drug is a part of a concentrated solution. 
     
     
         40 . The microneedle patch of  claim 38 , wherein the drug is a part of a powder.