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This study presents a comprehensive workflow for fabricating polymeric microneedle arrays utilising ultrahigh-resolution 3-dimensional (3D) printing and silicone mould fabrication.<\/jats:p>\n                  <\/jats:sec>\n                  <jats:sec>\n                    <jats:title>Methods<\/jats:title>\n                    <jats:p>In this work, an extensive toolbox with over 75 distinct microneedle designs was created and sequentially fabricated from acryl using our workflow based on ultrahigh-resolution 3D printing.<\/jats:p>\n                  <\/jats:sec>\n                  <jats:sec>\n                    <jats:title>Results<\/jats:title>\n                    <jats:p>\n                      The microneedle design parameters included obelisk and cone-like shapes, various lengths, base and tip diameters, and different densities. We systematically assessed the optimal design parameters for effective penetration of\n                      <jats:italic>ex vivo<\/jats:italic>\n                      human skin explants.\n                    <\/jats:p>\n                  <\/jats:sec>\n                  <jats:sec>\n                    <jats:title>Conclusion<\/jats:title>\n                    <jats:p>\n                      Our workflow, combined with application in an\n                      <jats:italic>ex vivo<\/jats:italic>\n                      human skin model, allows systematic comparison of multiple microneedle design parameters for efficacy. This work demonstrates the potential of this systematic modelling and ultrahigh-resolution 3D printing approach to optimize microneedles for intradermal biomedical applications, including therapeutic cancer vaccination.\n                    <\/jats:p>\n                  <\/jats:sec>\n                  <jats:sec>\n                    <jats:title>Graphical Abstract<\/jats:title>\n                  <\/jats:sec>","DOI":"10.1007\/s11095-025-03936-x","type":"journal-article","created":{"date-parts":[[2025,11,11]],"date-time":"2025-11-11T19:42:36Z","timestamp":1762890156000},"page":"2125-2143","update-policy":"https:\/\/doi.org\/10.1007\/springer_crossmark_policy","source":"Crossref","is-referenced-by-count":8,"title":["A Comprehensive Design-to-skin Pipeline to Fabricate Polymeric Microneedles Using Ultrahigh-resolution 3D Printing"],"prefix":"10.1007","volume":"42","author":[{"given":"Francesco","family":"La Malfa","sequence":"first","affiliation":[],"role":[{"vocabulary":"crossref","role":"author"}]},{"given":"Isabella A.","family":"van Hulst","sequence":"additional","affiliation":[],"role":[{"vocabulary":"crossref","role":"author"}]},{"given":"Ferry","family":"Ossendorp","sequence":"additional","affiliation":[],"role":[{"vocabulary":"crossref","role":"author"}]},{"given":"Urs","family":"Staufer","sequence":"additional","affiliation":[],"role":[{"vocabulary":"crossref","role":"author"}]},{"given":"Koen","family":"van der Maaden","sequence":"additional","affiliation":[],"role":[{"vocabulary":"crossref","role":"author"}]}],"member":"297","published-online":{"date-parts":[[2025,11,11]]},"reference":[{"key":"3936_CR1","doi-asserted-by":"publisher","DOI":"10.3390\/ijms20081811","author":"AV Nguyen","year":"2019","unstructured":"Nguyen AV, Soulika AM. 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