solid microneedles

Microneedles have emerged as a revolutionary tool in the field of biomedical engineering, offering a minimally invasive method for transdermal drug delivery, biosensing, and other medical applications including aesthetics.

As technology and medical practice advance, our customers are developing new and innovative solutions while designing their future devices, Tecan helps co-develop these mission critical metal components.

see also: Solid microneedles application note

painless and minimally invasive: They penetrate the skin without reaching nerves and blood vessels, ensuring a painless and bloodless application.

reduced risk of infection: Unlike traditional hypodermic needles, microneedles minimise the risk of sharps injuries and infections as they are bio-inert.

versatile: They can be tailored for various biomedical applications, including drug delivery, biosensing, and aesthetics.

Working with bio-inert metals such as stainless steel 316L or conductive materials plated to further enhance properties our skilled technicians ensure that an etch allowance is applied to all dimensions to account for ‘undercut’ where etching affects the edge of the photoresist in the chemical etching process, so ensuring precise measurement. This ensures high dimensional accuracy and tight tolerances.

Tecan produces solid metallic microneedles for use in transdermal systems. Solid microneedles fabricated through chemical etching possess several distinct characteristics that make them suitable for various biomedical applications. Our chemical etching process allows for the precise control of microneedle dimensions, ensuring uniformity and consistency in the final product.

Solid metallic microneedles can be produced in-plane or out of plane (for Micro Array Patches) and are superior to non-metallic microneedles for penetrating the skin barrier, the stratum corneum (10-20μm) for consistent delivery into the viable dermis and dermis layers.

precision and sharpness: Chemical etching allows for the creation of microneedles with precise dimensions and sharp tips. This precision is crucial for ensuring uniformity and effective skin penetration with minimal discomfort.

surface smoothness: The etching process can produce microneedles with smooth surfaces, which is beneficial for reducing friction during skin penetration and minimisng tissue damage.

customisation: Chemical etching allows for the customisation of microneedle arrays in terms of size, shape, and density. This flexibility enables the design of microneedles for specific therapeutic needs and target areas. Structures can be designed “in plane” or “out of plane” – e.g. Micro Array Patch (MAP)

material versatility: The choice of material can be tailored to the specific application, whether it be for drug delivery, biosensing, or cosmetic treatments. Important factors include strength and corrosion -resistance and conductivity properties We specialise in coatings including gold and Palladium plating of electrode microneedles.

biocompatibility: Microneedles made from bio-inert materials ensure that they do not cause adverse reactions when inserted into the skin. This is essential for applications involving drug delivery and long-term monitoring.

cost-effectiveness: using digital tooling, chemical etching is a repeatable, cost-effective method for producing microneedles, especially when compared to other fabrication techniques like laser ablation or lithography.

scalability: This method is highly scalable, making it suitable for large-scale production.

As technology and medical practice advance, the market is developing new and innovative solutions while designing future devices.

frequently asked questions

Does Tecan manufacture solid metallic microneedles?

Yes. Tecan manufactures solid metallic microneedles by photochemical etching, producing sharp, burr-free needles in bio-inert metals for transdermal drug delivery, biosensing and aesthetic devices.

What are solid metallic microneedles used for?

Solid metallic microneedles are used for transdermal drug delivery, continuous biosensing (such as glucose and lactate monitoring), and cosmetic and dermatology treatments such as dermarollers and dermapens.

What metals are Tecan’s microneedles made from?

Tecan makes microneedles from bio-inert metals such as stainless steel 316L, and can apply coatings including gold for electrode (biosensing) microneedles.

How sharp are Tecan’s microneedle tips?

Tecan produces microneedles with sharp, precise tips down to 5µm, etched to high dimensional accuracy for effective, comfortable skin penetration.

Can Tecan make microarray patches (MAPs)?

Yes. Tecan produces solid metallic microneedles in-plane or out-of-plane, including as microarray patches, with array size, shape and density customised to the application.

Why use photochemical etching to make microneedles?

Photochemical etching gives precise, repeatable control of microneedle dimensions and produces sharp, smooth, burr-free needles. Because it uses digital tooling, it is cost-effective and scalable for mass production.

Are Tecan’s microneedles bio-inert?

Tecan makes microneedles from bio-inert metals such as stainless steel 316L, which do not cause adverse reactions when inserted into the skin — important for drug delivery and long-term monitoring.

Can Tecan co-develop a custom microneedle design?

Yes. Tecan works with device makers to co-develop and deliver microneedle components, producing prototypes directly from drawings and scaling the same design to volume.

How do I request a quote for microneedles?

Send your drawings, material, quantity and tolerances via the Request a Quote page and Tecan will provide a quotation.