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

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.