3D printed microneedle patches using stereolithography (SLA) for intradermal insulin delivery

3D printed microneedle arrays were fabricated using a biocompatible resin through stereolithography (SLA) for transdermal insulin delivery. Microneedles were built by polymerising consecutive layers of a photopolymeric resin. Thin layers of insulin and sugar alcohol or disaccharide carriers were formed on the needle surface by inkjet printing. The optimization of the printing process resulted in superior skin penetration capacity of the 3D printed microneedles compared to metal arrays with minimum applied forces varying within the range of 2 to 5 N. Micro-CT analysis showed strong adhesion of the coated films on the microneedle surface even after penetration to the skin. In vivo animal trials revealed fast insulin action with excellent hypoglycaemia control and lower glucose levels achieved within 60 min, combined with steady state plasma glucose over 4 h compared to subcutaneous injections.