Patent ID: 8246893

Claim:
A method of molding a microneedle array comprising: (i) providing a mold apparatus comprising: a mold insert having the negative image of at least one microneedle; a compression core; and a mold housing configured to allow a reciprocal motion between the mold insert and the compression core, wherein the mold apparatus has an open position and a closed position; (ii) placing the mold apparatus in the closed position; (iii) applying acoustic energy having a frequency greater than about 5,000 Hz to the mold apparatus; (iv) injecting polymeric material into the closed mold apparatus; (v) compressing the injected polymeric material between the mold insert and the compression core by a reciprocal motion between the compression core and the mold insert; (vi) opening the mold; and (vii) removing the molded microneedle from the mold.