Extended Data Fig. 5: Alternate printer configurations and MNP demolding.

(a) Throughput of automated MNP fabrication can be increased by modular moving trays of MNP molds to a drying rack to expedite the vaccine drying step. Vacuum-through application to fill the microneedle mold can occur either on the mold transport device (middle) or in the tray rack (right). (b) Drying throughput is presented as a function of tray length and the number of trays in the vertical drying rack. Size (h) of the drying rack was estimated assuming a single tray height of 50 mm. Like the single tray device, drying time is assumed to be 48 h. (c) PDMS molds can be pretreated with a degassing technique using negative pressure prior to vaccine dispensing for an expedited MNP fabrication process. With degassed PDMS molds, a robotic arm can dispense vaccine solution in a continuous manner. Fully dispensed PDMS molds can then be moved to a drying rack using a conveyer belt. This entire process will be contained within an aseptic enclosure to maintain sterility during processing. (d–i) Design for automated patch demolding. (d) After vaccine microneedle patches are fully dried in a PDMS mold, (e) a robotic arm brings an acrylic backing with double-sided tape. (f) The robotic arm aligns and attaches the acrylic adhesive backing to a microneedle patch, (g) and the MNP is removed from PDMS mold as the robotic arm is raised vertically. (h) The tip of the robotic arm enters between a metal slit designed for MNP removal. As the robotic arm raises vertically, the MNP detaches from the robot arm tip and falls into its packaging (i), where the MNP is hovering to prevent any direct contact with the needle tips. Demolded MNPs are packaged and stored in a sterile and dry environment until use.