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<p>Sharp microneedle (MN) tips are crucial for reliable penetration; yet, tip resolution is limited by stereolithography (SLA) printing. We present an aspect ratio–guided printing angle optimization method in which the final layer, including MN tips, is aligned with the Z-axis. Optimal angles for conical, square, and hexagonal MNs of aspect ratios 2:1, 3:1, and 4:1 (75.96°, 80.54°, 82.88°) were calculated. This approach yielded 30% sharper tips than conventional orientations, with conical MNs consistently achieving ~20&#xa0;µm diameters. By turning SLA’s layer-by-layer limitation into an asset, this framework offers a predictive and transferable design tool for MN production.</p> Graphical abstract <p></p>

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An aspect ratio–guided printing angle optimization framework for 3D-printed microneedles

  • 期刊论文

  • 发表日期：

    2026年4月27日

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  • Emre Ece,
  • Shammas Mohamed,
  • Eylul Gulsen Yilmaz,
  • Dilsad Taydas,
  • Nedim Hacıosmanoğlu,
  • Fatih Inci

摘要

Sharp microneedle (MN) tips are crucial for reliable penetration; yet, tip resolution is limited by stereolithography (SLA) printing. We present an aspect ratio–guided printing angle optimization method in which the final layer, including MN tips, is aligned with the Z-axis. Optimal angles for conical, square, and hexagonal MNs of aspect ratios 2:1, 3:1, and 4:1 (75.96°, 80.54°, 82.88°) were calculated. This approach yielded 30% sharper tips than conventional orientations, with conical MNs consistently achieving ~20 µm diameters. By turning SLA’s layer-by-layer limitation into an asset, this framework offers a predictive and transferable design tool for MN production.

Graphical abstract