Predicting the replication fidelity of injection molded solid polymer microneedles

Abstract Microneedles are sharp microscopic features, which can be used for drug or vaccine delivery in a minimally invasive way. Recently, we developed a method to produce polymer microneedles using laser ablated molds in an injection molding process. At this moment, extensive injection molding experiments are needed to investigate the replication fidelity. Accurate predictions of the injection molding process would eliminate these costly and time expensive experiments. In this study, we evaluated the replication fidelity of solid polymer microneedles using numerical simulations and compared the results to injection molding experiments. This study was performed for different sizes of microneedles, different thermoplastics (polypropylene and polycarbonate) and different mold materials (tool steel, copper alloy and aluminium alloy). Moreover, different processing conditions and different locations of the microneedles on the macroscopic part were considered. A good correlation with experimental findings was achieved by optimizing the heat transfer coefficient between the polymer and the mold, while using a multiscale mesh with a sufficient number of mesh elements. Optimal heat transfer coefficients between 10,000 and 55,000 W/m 2 K were found for the different combinations of polymer and mold materials, which resulted in an accuracy of the simulated microneedle replication fidelity between 94.5 and 97.0%.