This study presents a low-cost 3D printing method for fabricating high-quality biodegradable polymeric microneedle (MN) arrays with superior mechanical strength for transdermal drug delivery applications. The MN arrays were fabricated using stereolithography (SLA) with different aspect ratios (2:1, 3:1, and 4:1). The 3D-printed molds were developed using polydimethylsiloxane (PDMS) material, and the biodegradable MN arrays were produced using these molds. The printing accuracy of the MN arrays was evaluated using optical and scanning electron microscopes, while mechanical strength and insertion tests were conducted to assess the performance of the MNs. The results showed that MNs with higher aspect ratios had higher deformation characteristics suitable for penetration beyond the stratum corneum. MNs with base diameters of 0.3 mm and 0.4 mm exhibited consistent force–displacement behavior during skin-equivalent penetration tests. The study established guidelines for fabricating polymeric MNs for high-accuracy and low-cost 3D printing. The MN arrays demonstrated mechanical robustness and the ability to penetrate the skin for drug delivery. The research also compared the AM method with laser ablation, highlighting the advantages of AM in terms of design flexibility and customization. The study identified the optimal tip diameter for MNs based on their base diameter and aspect ratio. The results indicated that the fabricated MN arrays could effectively penetrate the stratum corneum and reach the dermis layer for drug delivery applications. The study also discussed the limitations and future work, including the need for further investigation into drug release content and in vivo studies. Overall, the research provides a framework for the design and manufacturing of biodegradable MN arrays for therapeutic applications.This study presents a low-cost 3D printing method for fabricating high-quality biodegradable polymeric microneedle (MN) arrays with superior mechanical strength for transdermal drug delivery applications. The MN arrays were fabricated using stereolithography (SLA) with different aspect ratios (2:1, 3:1, and 4:1). The 3D-printed molds were developed using polydimethylsiloxane (PDMS) material, and the biodegradable MN arrays were produced using these molds. The printing accuracy of the MN arrays was evaluated using optical and scanning electron microscopes, while mechanical strength and insertion tests were conducted to assess the performance of the MNs. The results showed that MNs with higher aspect ratios had higher deformation characteristics suitable for penetration beyond the stratum corneum. MNs with base diameters of 0.3 mm and 0.4 mm exhibited consistent force–displacement behavior during skin-equivalent penetration tests. The study established guidelines for fabricating polymeric MNs for high-accuracy and low-cost 3D printing. The MN arrays demonstrated mechanical robustness and the ability to penetrate the skin for drug delivery. The research also compared the AM method with laser ablation, highlighting the advantages of AM in terms of design flexibility and customization. The study identified the optimal tip diameter for MNs based on their base diameter and aspect ratio. The results indicated that the fabricated MN arrays could effectively penetrate the stratum corneum and reach the dermis layer for drug delivery applications. The study also discussed the limitations and future work, including the need for further investigation into drug release content and in vivo studies. Overall, the research provides a framework for the design and manufacturing of biodegradable MN arrays for therapeutic applications.