Using IPFL's high-resolution micro 3D printing expertise, our clients accelerate the development of next-generation microneedle arrays for transdermal drug delivery, diagnostics, and cosmetic applications.
With more than 50 years of experience, IPFL is at the forefront of micro-scale fabrication technology. Using advanced Projection Micro Stereolithography (PµSL), we produce microneedle arrays with the sharp tips, high-aspect-ratio shafts and consistent geometry needed for next-generation drug delivery, vaccination, diagnostic and cosmetic devices. Our microneedle prototyping and production services support medical device companies, pharmaceutical formulators and research teams developing solid, hollow, coated and dissolving microneedle systems, taking projects from early-stage feasibility through to manufacture-ready masters.
At IPFL, we leverage our extensive experience in micro-scale manufacturing to provide precision microneedle arrays for the medical device, pharmaceutical and cosmetic sectors. Whether your project involves an early-stage feasibility prototype or a design destined for scaled production, we offer tailored solutions that meet the highest standards of innovation and quality.
Microneedle Arrays Defined Microneedle arrays are patches of micron-scale needles, typically ranging from around 200µm to 1500µm in height, designed to painlessly penetrate the outer layers of skin. They are used to deliver drugs and vaccines, extract biomarkers for diagnostic monitoring, or enhance the absorption of topical actives, without reaching the nerve endings found deeper in the dermis.
At IPFL, we manufacture microneedle arrays to suit a wide range of clinical and consumer applications. Each design is optimised for its intended skin-penetration depth, payload and release profile.
Our capabilities include high-resolution micro 3D printing, CNC machining and diffusion bonding, enabling production of intricate needle geometries and fully assembled delivery devices. Explore the design options below or return to the main microneedle arrays page for a full overview of our technologies and capabilities.
Solid Microneedles: Solid microneedles create micro-channels in the skin to enhance the permeability of topically applied drugs, vaccines or cosmetic actives. IPFL produces solid arrays with sharp, high-aspect-ratio tips for consistent, minimally invasive penetration.
Hollow Microneedles: Hollow microneedles incorporate an internal bore for the direct delivery of liquid formulations beneath the skin’s surface. We combine micro 3D printing with diffusion bonding to create leak-free fluid pathways from reservoir to needle tip.
Coated Microneedles: Coated microneedles carry a dry drug or vaccine layer on the needle surface, which dissolves once inserted into the skin. IPFL prototypes the underlying needle geometry to optimise surface area and coating uptake.
Dissolving Microneedles: Dissolving microneedles are fabricated from biocompatible, water-soluble polymers that dissolve fully in the skin, releasing their payload and leaving no sharps waste. We 3D print precision masters that support replication into dissolving polymer formats.
