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However, clinical translation faces a critical bottleneck: the absence of stable, cost\u2010effective, scalable high\u2010precision manufacturing technologies. This work systematically establishes a comprehensive end\u2010to\u2010end solution encompassing precise molding and functional integration. We employed injection\u2010compression molding with multi\u2010objective optimization algorithms to elucidate relationships between critical process parameters and HMN array molding quality. The results demonstrate that positioning the HMN array at the far\u2010gate locations enhances filling quality and reduces core\u2010pin impact force by 15%, revealing the underlying physical mechanisms governed by shear heating effects and pressure transmission dynamics, which enriches conventional micro\u2010injection molding theory. The optimized process achieves &gt;6.8% filling ratio improvement and 10% injection pressure reduction. Furthermore, we established a complete design and fabrication workflow for ISF extraction chips, developed patterned microelectrode bonding technology for complex microchannel sealing, and validated in situ detection platform advantages. In vitro testing validated safe and efficient ISF extraction with a 95% success rate while maintaining exceptional portability for wearable health monitoring applications. This work provides theoretical and practical guidance for scalable HMN manufacturing, establishing a foundation for commercializing next\u2010generation continuous health monitoring systems.<\/jats:p>","DOI":"10.1002\/smll.76125","type":"journal-article","created":{"date-parts":[[2026,10,9]],"date-time":"2026-10-09T12:54:11Z","timestamp":1791550451000},"update-policy":"https:\/\/doi.org\/10.1002\/crossmark_policy","source":"Crossref","is-referenced-by-count":0,"title":["Precision Injection\u2010Compression Molding and Functional Integration of Hollow Microneedle Microfluidic Chips for Minimally Invasive Continuous Health Monitoring"],"prefix":"10.1002","author":[{"ORCID":"https:\/\/orcid.org\/0000-0001-7530-8630","authenticated-orcid":false,"given":"Baishun","family":"Zhao","sequence":"first","affiliation":[{"name":"State Key Laboratory of Precision Manufacturing for Extreme Service Performance School of Mechanical and Electrical Engineering Central South University  Changsha 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