A mold assembly for forming a microneedle array exhibiting different aspect ratios is described. The mold assembly comprises a plurality of laminate mold layers 102, each of the laminate mold layers having a plurality of laminate recesses 104 and wherein the plurality of laminate recesses cooperate with an adjacent laminate mold layer to define a plurality of laminate cavities, and a base mold portion 111 having a base cavity configured to be disposed adjacent the plurality of laminate cavities such that the base cavity and the laminate cavities cooperate to define a mold for a microneedle array, wherein at least a portion of the plurality of laminate cavities vary in size relative to each other to provide a varying aspect ratio.
