Fs laser ablation and injection molding simulations for the manufacturing of polymer hollow microneedles

Abstract:This paper presents a comprehensive simulation-based approach for the manufacturing of polymer hollow microneedles (HMNs) using femtosecond (fs) laser ablation and injection molding (IM) techniques. Microneedles represent a promising alternative for transdermal drug delivery; however, their fabrication faces challenges related to reproducibility, quality, and efficiency. These challenges are addressed through a dual modeling framework. The first part details the adaptation and validation of a three-dimensional pulse-by-pulse model based on the two-temperature model for predicting the geometries of HMN cavities created via fs laser ablation. This model demonstrates accuracy in simulating critical parameters such as depth, base width, and surface texture. The second part employs Moldex3D for IM simulations, focusing on the heat transfer coefficient and venting boundary conditions that impact the replication fidelity of HMNs. This simulation accurately predicts needle heights after implementing a methodology for correcting entrapped air volume. By integrating both simulation tools, active development time can be reduced by 70%, and equipment requirements are significantly lowered compared to traditional methods. The findings underscore the potential of these simulations to streamline the manufacturing process, enhance microneedle quality, and support tailored biomedical applications.

Publication year:2025

Keywords:Electrical & electronic engineering, General & traditional engineering

Accessibility:Open

Review status:Peer-reviewed