Toward Predictive Modeling of Microneedle Design: Establishing a Correlation Between CAD Models, 3D Printed Arrays, and PDMS Molds

Tiwari, V. K.; Tabassum, S.

doi:10.1101/2025.04.05.647392

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bioRxiv · 10.1101/2025.04.05.647392

Toward Predictive Modeling of Microneedle Design: Establishing a Correlation Between CAD Models, 3D Printed Arrays, and PDMS Molds

Tiwari, V. K.·Tabassum, S.

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Abstract

Microneedles are increasingly gaining traction in transdermal delivery systems, with precision in geometry being a key determinant of their efficacy. In this study, we aim to establish a quantitative and visual correlation between computer-aided design (CAD) models, 3D printed microneedle arrays fabricated using the Formlabs 3B SLA printer, and polydimethylsiloxane molds casted from the printed arrays. The goal is to develop a predictive framework that allows designers to fine-tune CAD geometries based on desired final outputs, bypassing iterative prototyping. The study presents a methodology involving dimensional analysis across fabrication stages and highlights deformation trends inherent in each stage, laying the groundwork for data-driven reverse design approaches.

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Tiwari, V. K., Tabassum, S.. 2025-04-09. Toward Predictive Modeling of Microneedle Design: Establishing a Correlation Between CAD Models, 3D Printed Arrays, and PDMS Molds. https://doi.org/10.1101/2025.04.05.647392

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