A method for manufacturing microneedle devices and systems and tools for implementing same. The method can include manufacturing a replica mold and forming a microneedle array via the replica mold. The replica mold can be manufactured by disposing replica mold material on a master mold and curing the replica mold material. To reduce manufacturing time, the replica mold material preferably is cured at a high temperature for a relatively short time and then cooled quickly before removal from the master mold. The microneedle array can be formed by disposing microneedle material on the replica mold under vacuum and drying the microneedle material in single or successive disposing and drying operations. One or more optional backing layers can be added to the microneedle array when forming the microneedle device. Advantageously, the disclosed methods, systems and tools can be used to manufacture skin-applied patches for delivering cosmetic and therapeutic agents.

A production method of a mold includes: preparing a plate precursor having a protruding pattern formed of protrusions in a pattern presence region on a base, and a thermoplastic resin sheet; determining a position at which the plate precursor is to be pressed against the thermoplastic resin sheet by moving the plate precursor and the thermoplastic resin sheet relative to each other; and forming a recessed pattern on the thermoplastic resin sheet by pressing the protrusions of the plate precursor which is heated against the thermoplastic resin sheet at a position where a part of the pattern presence region of the plate precursor excluding the protrusions is separated from a surface of the thermoplastic resin sheet, cooling the plate precursor in a state in where the pressed protrusions and the thermoplastic resin sheet are in contact with each other, and separating the plate precursor from the thermoplastic resin sheet.

A method for producing a needle-shaped body having needles on a first surface of a substrate made of a thermoplastic resin, the method including the steps of: forming the needle-shaped body by filling the thermoplastic resin into a duplication plate having recesses that correspond to shapes of the needles; providing a support member made of a material different from a material for the needle-shaped body on a second surface of the substrate which is opposite to the first surface; and removing the needle-shaped body and the support member which are integrally formed from the duplication plate.

Acupuncture needles may be used for piercing tissue with less trauma than may occur when employing larger gauge needles. However, because acupuncture needles are fabricated and packaged differently than are larger gauge needles, acupuncture needles may be less compatible with certain manufacturing processes. Needle assemblies compatible with manufacturing processes may comprise a continuous support material having a plurality of apertures defined therein, and a first injection molded coupler that surrounds a proximal portion of an acupuncture needle and connects the acupuncture needle to a first location upon the continuous support material, such that the acupuncture needle is held in a pre-determined orientation with respect to a longitudinal axis of the first injection molded coupler. The acupuncture needles in adjacent apertures may also be spaced apart substantially uniformly.

A method for manufacturing a needle-shaped body, including supplying a first aqueous solution to an intaglio plate, supplying a second aqueous solution to the intaglio plate, drying the first and second aqueous solutions in the intaglio plate such that a dried body is formed on the intaglio plate, and separating the dried body from the intaglio plate such that a needle-shaped body including a needle-shaped projection and a support base which supports the needle-shaped projection is obtained. The intaglio plate includes a recess corresponding to the needle-shaped projection, the first aqueous solution is supplied to fill at least a portion of the recess, the first aqueous solution and the second aqueous solution are immiscible, the first aqueous solution forms a projection side layer in the needle-shaped body, and the second aqueous solution forms a support base side layer on the projection side layer in the needle-shaped body.

Acupuncture needles may be used for piercing tissue with less trauma than may occur when employing larger gauge needles. However, because acupuncture needles are fabricated and packaged differently than are larger gauge needles, acupuncture needles may be less compatible with certain manufacturing processes. Needle assemblies compatible with manufacturing processes may comprise a continuous support material having a plurality of apertures defined therein, and a first injection molded coupler that surrounds a proximal portion of an acupuncture needle and connects the acupuncture needle to a first location upon the continuous support material, such that the acupuncture needle is held in a pre-determined orientation with respect to a longitudinal axis of the first injection molded coupler. The acupuncture needles in adjacent apertures may also be spaced apart substantially uniformly.

Acupuncture needles may be used for piercing tissue with less trauma than may occur when employing larger gauge needles. However, because acupuncture needles are fabricated and packaged differently than are larger gauge needles, acupuncture needles may be less compatible with certain manufacturing processes. Needle assemblies compatible with manufacturing processes may comprise a continuous support material having a plurality of apertures defined therein, and a first injection molded coupler that surrounds a proximal portion of an acupuncture needle and connects the acupuncture needle to a first location upon the continuous support material, such that the acupuncture needle is held in a pre-determined orientation with respect to a longitudinal axis of the first injection molded coupler. The acupuncture needles in adjacent apertures may also be spaced apart substantially uniformly.

A decorative panel includes a mineral layer, and a decorative surface. The decorative surface has an embossed pattern, wherein the embossed pattern is provided in the mineral layer.