A method of forming a microneedle array comprising disposing a first curved laminate 100 adjacent an embossing roll 101. The laminate comprises a body having a first longitudinal side and a second longitudinal side extending from a curved base. The first longitudinal side comprises a plurality of recesses 111 disposed adjacent a periphery of the first longitudinal side. At least a second curved laminate 105 is disposed adjacent the embossing roll, defining a plurality of cavities 208 there between. A material is extruded at one or more of the first and second curved laminates. At least a portion of the embossing roll is heated at a point of contact between the material and one or more of the first and second curved laminates. The material is caused to move into the plurality of cavities forming a plurality of projections at a surface of the material and the material is demolded.
