Improved microneedle arrays are provided having a sufficiently large separation
distance between each of the individual microneedles to ensure penetration of the
skin while having a sufficiently small separation distance to provide high transdermal
transport rates. A very useful range of separation distances between microneedles
is in the range of 100-300 microns, and more preferably in the range of 100-200
microns. The outer diameter and microneedle length is also very important, and
in combination with the separation distance will be crucial as to whether or not
the microneedles will actually penetrate the stratum corneum of skin. For circular
microneedles, a useful outer diameter range is from 20-100 microns, and more preferably
in the range of 20-50 microns. For circular microneedles that do not have sharp
edges, a useful length for use with interstitial fluids is in the range of 50-200
microns, and more preferably in the range of 100-150 microns; for use with other
biological fluids, a useful length is in the range of 200 microns-3 mm, and more
preferably in the range of 200-400 microns. For circular microneedles having sharp
side edges, a useful length for use with interstitial fluids is in the range of
50-200 microns, and more preferably in the range of 80-150 microns; for use with
other biological fluids, a useful length is again in the range of 200 microns-3
mm, and more preferably in the range of 200-400 microns. For solid microneedles
having a star-shaped profile with sharp edges for its star-shaped blades, a useful
length for use with interstitial fluids is in the range of 50-200 microns, and
more preferably in the range of 80-150 microns; for use with other biological fluids,
a useful length is again in the range of 200 microns-3 mm, and more preferably
in the range of 200-400 microns, while the radius of each of its blades is in the
range of 10-50 microns, and more preferably in the range of 10-15 microns.