Multilayer riblet applique and methods of producing the same are described herein. One disclosed example method includes applying a first high elongation polymer material to a web tool, where the web tool is to be provided from a first roll, and heating, via a first heating process, the first high elongation polymer material. The disclosed example method also includes applying a second high elongation polymer material to the first high elongation polymer material, and heating, via a second heating process, the second high elongation polymer material. The disclosed example method also includes applying, via a laminating roller, a support layer to the second high elongation polymer material.

The present invention provides a microneedle array, a support member, a method of producing a microneedle array, and a microneedle array unit which enable reduction of a drying time during production and prevention of breakage during drying. Provided are a microneedle array 120 including a sheet portion 41, a plurality of needle-like protrusions 44, and a support member 50 formed of a gripping portion 52 and a beam portion 54 having one end that is connected to the gripping portion 52, in which the sheet portion 41 is an integrally molded body which is integrally molded with the support member 50, in which at least a part of the beam portion 54 is buried under the other surface 43 of the sheet portion 41, opposite to the one surface where the needle-like protrusions 44 are provided, the gripping portion 52 is provided on the other surface 43 of the sheet portion 41, and the beam portion 54 is deformable toward a center of the sheet portion 41. Further, provided are the support member 50, a method of producing the microneedle array 120, and a microneedle array unit 300 including a container 310.

A method for manufacturing a microfluidic device can include providing a base component to define a first portion of the microfluidic device. A cap component of the microfluidic device can be fabricated with a sealing lip extending a first distance from a first side of the cap component and a support portion extending a second distance, less than the first distance, from the first side of the cap component. The method can include positioning the cap component and the base component within a mold to bring the sealing lip of the cap component in contact with the base component. The base component, the support portion of the cap component, and the sealing lip of the cap component together can define a cavity. The method can include injecting a polymer material into the mold to cause the polymer material to fill the cavity.

A microneedle assembly and a method of fabrication the assembly are provided. The microneedle assembly includes an array of microneedles attached to a base. Each of the microneedles comprise a tip, a needle shaft and a plurality of cantilevered barbs protruding outwardly from the needle shaft, where a plurality of the microneedles include two or more of the cantilevered barbs arranged in a series of concentric rings along the needle shaft of each of the plurality of microneedles. The microneedle assembly may be fabricated using a 3D printing technique, where one or more cantilevered layers are formed by exposing a photocurable liquid resin including monomer material to a light source to create initially horizontal, cantilevered barbs having a crosslinking gradient, and rinsing to remove an amount of un-crosslinked monomers from the cantilevered layers to induce curvature in the cantilevered barbs extending towards a direction of the lower crosslinking.

Provided herein is a hierarchical superhydrophobic surface comprising an array of first geometrical features disposed on a substrate comprising a first material and a terminal level disposed on the second features, wherein the terminal level comprises a second material, the second material being different from the first material. The second material has a hydrophilicity different from the hydrophilicity of at least one of 1) the hydrophilicity of the second material and 2) hydrophilicity induced by the hierarchical structure. The present disclosure further includes methods of preparing hierarchical superhydrophobic surfaces and medical devices comprising the hierarchical superhydrophobic surfaces.

A fluid device composite member includes: a silicone member that includes a body part which is made of silicone and which has a flow-path-defining section for defining a flow path on one surface of the body part, and that includes barrier layer having hydrophilicity or hydrophobicity disposed in at least a portion of the flow-path-defining section; and a resin substrate disposed on another surface of the body part opposite to the one surface. This method for manufacturing the fluid device composite member includes a layered body manufacturing step in which a liquid silicone material is placed on a surface of the resin substrate, and the liquid silicone material is cured at a temperature of 100° C. or less to obtain a layered body in which a silicone cured product is bonded to the resin substrate.

Provided is an inexpensive microneedle array with little dimensional error that can control, with high precision, the amount of a predetermined component to be introduced to the inner part of the skin, and a production method for this microneedle array. A foundation that is insoluble or sparingly soluble in inner part of the skin is overlaid on a mold. A plurality of frustum-shaped protrusions, which are insoluble or sparingly soluble in the raw material liquid, provided on a first main surface of the foundation are fit into a plurality of cone-shaped recesses. The raw material liquid in the plurality of cone-shaped recesses dries and, as a result, a plurality of microneedles, which are dissolvable in the inner part of the skin, are fixed to tip surfaces of the plurality of frustum-shaped protrusions.

A production method of a mold having a recessed pattern includes: a plate precursor preparation step of preparing a plate precursor having a pedestal on which a protruding pattern is disposed; a resin plate preparation step of preparing a thermoplastic resin plate having a recessed step portion; and a resin plate precursor production step of producing a thermoplastic resin plate precursor, the resin plate precursor production step including a positioning step of positioning the protruding pattern of the plate precursor and a center position of the recessed step portion, and a recessed pattern forming step of forming a recessed pattern having an inverted shape of the protruding pattern on the thermoplastic resin plate by pressing the protruding pattern of the heated plate precursor and the pedestal against the recessed step portion, thereafter cooling the plate precursor, and separating the plate precursor from the thermoplastic resin plate.

Methods are provided that involve the intentional and controlled precipitation of a drug or active agent, or a reduction of solubility of a polymer or other film-forming component of a formulation, or a combination of both methods, to improve the processes for making microneedles or other objects by casting into molds and the resulting parts produced by casting. The selective reduction in solubility of formulation components solves many problems associated with the casting of polymer formulations into molds. The methods are preferably adapted for making microneedles of biodegradable polymer and drug composites, and may also be used to produce other solid objects formed by casting into molds of compositions containing polymers and active agents.

A method of filling a microcavity with layers of a polymer material includes the following steps: (A) estimating a current vertical position of a bottom of the microcavity (current bottom position); (B) lowering the capillary tube into the microcavity towards the current bottom position; (C) dispensing a polymer composition from a tube outlet of the capillary tube under a dispensing applied pressure until the polymer composition substantially fills the microcavity; (D) curing a work piece including the microcavity and the polymer composition in the microcavity to obtain a current layer of the polymer material; and (E) repeatedly executing steps (A), (B), (C), and (D), until the layers of the polymer material have substantially filled the microcavity.