Method and apparatus for fabricating brittle microneedle

A microneedle array comprising:

• a plurality of microneedles;
• the microneedles comprising an elongated body portion terminating in a tip;
• the microneedles comprising a biocompatible material;
• and
• the microneedles coupled to a polymeric backing layer;
• the polymeric backing layer having an elastic modulus that is lower than the elastic modulus of the elongated body portion of the microneedles.

A method of forming a microneedle array, wherein the microneedle array includes an elongated body portion terminating in a sharp tip, the elongated body portion coupled to a polymeric backing layer, the method comprising the steps of:

• powder coating a powdered biocompatible material to a microneedle mold;
• heating the biocompatible material;
• coupling a polymeric backing layer directly to a base surface of the heated mixture;
• cooling the heated mixture and back layer to form the microneedle array;
• wherein an elastic modulus of the polymeric backing layer is lower than an elastic modulus of the elongated body portion of the microneedles.