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The study introduces a finite element analysis (FEA)-guided co-design framework for developing separable bubble microneedles (BMNs) that optimize geometry and cavity parameters for controlled tip separation and robust insertion. The research demonstrated that minoxidil sulfate-loaded BMNs (MXS-BMNs) and insulin-loaded BMNs (INS-BMNs) achieved effective transdermal and sublingual delivery, respectively. MXS-BMNs showed a sevenfold increase in minoxidil permeation compared to topical gel and accelerated hair regrowth in mice, while INS-BMNs provided rapid glucose reduction in diabetic rats. The FEA predictions closely matched experimental results, confirming the framework's efficacy in reducing empirical iteration and expediting BMN development for rapid drug delivery.

The study introduces a finite element analysis (FEA)-guided co-design framework for developing separable bubble microneedles (BMNs) that optimize geometry and cavity parameters for controlled tip separation and robust insertion. The research demonstrated that minoxidil sulfate-loaded BMNs (MXS-BMNs) and insulin-loaded BMNs (INS-BMNs) achieved effective transdermal and sublingual delivery, respectively, with separation forces closely matching FEA predictions and axial strengths surpassing skin and mucosa penetration thresholds. In vivo tests showed MXS-BMNs significantly enhanced hair regrowth in mice, while INS-BMNs effectively lowered glucose levels in diabetic rats. This approach reduces empirical iteration, facilitating the rapid development of efficient microneedle systems for drug delivery.