Parametric Rule-Based Intelligent System (PRISM) for Design and Analysis of High-Strength Separable Microneedles

This study presents PRISM (Parametric Rule-Based Intelligent System), a computational platform integrating parametric 3D modeling, structural analysis, and high-resolution micro-3D printing for the design of high-strength separable microneedles. PRISM automatically generates tunable 3D geometries based on user inputs (barb number, tip angle, neck ratio, and cavity size) and predicts output metrics including surface area, volume, and cross-sectional area at the neck to optimize mechanical robustness and separability. Prototypes fabricated via projection microstereolithography (pµSL) showed sub-5 µm printing precision and <5% dimensional error from CAD models. The optimized design (Group D) with a narrowed neck, internal cavity, and triple-barb reinforcement achieved 2.13 ± 0.51 N axial strength and 73.92 ± 34.77 mN shear fracture force—outperforming conventional geometries. Skin phantom tests confirmed reliable tip detachment and retention, validating PRISM as a rapid design–testing pipeline for transdermal delivery.