Method and apparatus for manufacturing a device

An apparatus for making a molded device comprising a plurality of micron or sub-micron size structural features, said apparatus comprising:

• a means for containing a mold assembly having a mold section with a recess defining a mold cavity and having a silicon mold member disposed in said mold recess, said silicon mold member having a mold surface with a contoured surface defining an impression of said device and said structural features facing said mold cavity, wherein said silicon mold member is adapted for releasing said molded device from said mold section;
• a means for introducing a plastic material into said means for containing said mold assembly, to fill said mold cavity and said contoured surface in said silicon maid member to form said molded device having a body and molded surface corresponding to said contoured surface and said structural features.

A mold assembly for forming a molded medical device having at least one sham edge, said mold assembly comprising:

• a mold section with a recess;
• a silicon mold member, having a mold surface, said mold surface having a contoured surface including at least one needle forming recess and said mold surface defining an impression for molding at least a portion of said medical device;
• wherein said mold section and said silicon mold member define at an operable mold cavity, and said silicon mold member is disposed in said recess of said mold section, and said mold surface of said silicon mold member is facing said mold cavity, said mold cavity having a closed state and an open state, wherein when said mold cavity is in a closed state, a molding material is received by said mold cavity, thereby forming said molded medical device having at least one sharp edge.