Abstract The emergence of microneedle (MN) technologies offers a route for a pain free, straightforward and efficient way of transdermal drug delivery, but technological barriers still exist which pose significant challenges for manufacture of MN systems with high volume outputs at low cost. Our aim here is to develop new routes for MN manufacture using micro-injection and ultrasound moulding processes with high performance engineering thermoplastics (Poly ether ether ketone and Polycarbonate). For such small polymeric components, subjected to the extreme stress, strain rate and temperature gradients encountered in the micro-moulding process, detailed material characterisation combined with process monitoring is desirable to highlight variations in moulding conditions and this will assist in creating a viable manufacturing process with acceptable quality products. Polymeric MNs should have good mechanical strength to sustain the insertion force to pierce the human skin and delivery the drugs. Therefore it is of paramount importance to check the mechanical properties of the moulded microneedles. A depth-sensing nanoindentation devices allow the amount of penetration of an indenter into a material to be measured as a function of applied load. In this study a nano-indentation technique was employed to study the material hardness, contact depth and modulus of the moulded MN samples. The MNs manufactured from both the moulding processes were also dimensionally assessed were then geometrically assessed using a range of characterisation techniques such as atomic force microscopy, confocal microscopy and scanning electron microscopy. The output from these studies will be able to measure the responses of microscopic regions which can be a key to understanding mechanical behaviour of the polymeric microneedles. Keywords: Micro-injection moulding, microneedles, poly ether ether ketone, ultrasound moulding, polycarbonate and nanoindentation.