In biomedical engineering, microneedle arrays are widely used for transdermal medication delivery and biomarker extraction from human skin interstitial fluid. in addition to administering drugs and vaccines, microneedle arrays can be used to record and stimulate neural signals, treat skin conditions like scur and acne with collagen induction therapy, stimulate hair growth, treat skin cancer and tumours, treat mouth ulcers and retinal diseases, and extract biomarkers from the interstitial fluid for blood glucose measurement or other health indicators. many fabrication techniques have been devised to use metals, ceramics, and polymers to create microneedles in various sizes and forms. however, it is still difficult to produce mn arrays in sufficient quantities at a fair price. using moulds made of appropriate material and imprinting the negative geometry of the mn array onto them would likely be a solution to this problem. this method will make it simple and economical to fabricate solid, dissolvable, and hydrogel-forming mn arrays on a wide scale. the current study describes a method of fabricating microneedle arrays using wire electric discharge machining (wedm) with an in-house developed multifunctional fixture attachment. the microneedles were designed as a pyramid shape with exponentially decreasing width for better structural rigidity and requiring minimum force on application. a 5x5 array of microneedles with varying densities was created on ss316 substrate using a cnc-operated wedm and the in-house developed multifunction fixture attachment. a methodical experimental investigation was conducted about the offset between the microneedle faces and the programmed depth (pd) of the valleys between the microneedles with the known value (experimentally determined from the earlier work) of overcut associated with the wedm parameters. microneedle height (h), base width (bw), and tip width (tw) are the output parameters. minimum bw, minimum tw, and maximum h were found at pd = 1071.4µm and offset = 279µm. three confirmation tests at the optimal location were conducted, and it was found that the average needle tip width, base width, and height are 55.3 ±5 µm, 683.6 ±19 µm, and 914.7 ±19 µm, respectively. the error associated with the prediction model was found to be 0.33%, -1.2%, and 29.19% for microneedle height, base width, and tip width, respectively. high surface roughness is a common issue found in the surface produced by the wedm process. so, to improve the surface finish and to further sharpen the microneedle tips, electrochemical polishing was carried out on the microneedle samples with an in-house developed electropolishing setup. a separate study was performed to optimize the important input parameters, namely, time, electrolyte temperature, and inter-electrode gap, to get minimum thickness reduction and surface roughness. the optimum input process parameters were found to be electropolishing time = 30 min, inter-electrode gap = 4 mm, and electrolyte temperature = 45 °c with a thickness reduction of 8.66 µm. the surface roughness was found to be reduced by 51.43%. the microneedle height and base width were reduced to 756 µm and 535.05 µm, respectively, from the initial value of 918 µm and 684 µm. also, the microneedle tip width was reduced to 1.3 µm from an initial tip thickness of 55.3 µm (97.6% reduction) and is sharp enough to penetrate the skin. the fabricated solid (ss 316 substrate) microneedle array can be further used as a master pattern for the fabrication of moulds with a suitable material. these moulds can be used to fabricate solid, coated, dissolving, or hydrogel-forming microneedle arrays with a suitable polymeric material on a large scale. also, the shape and size of the microneedle can be changed by using different part programs in the cnc wedm and changing electochemical polishing parameters, thus offering flexibility in terms of design and choice of materials.