In the preferred embodiment, a method of making microneedles comprises i) providing a microneedle template (300) having a plurality of microneedles cavities (360) on one surface, ii) preparing a casting solution (320) comprising at least one matrix material and its solvent, iii) subjecting said microneedle template (300) to a vacuum pressure for a length of time to deprive it of air, iv) dispensing the casting solution (320) over the air-deprived microneedle template, v) allowing the casting solution (320) to be drawn into the air-deprived microneedle cavities (360) completely, and vi) allowing the dissolving microneedles to solidify or dry in a controlled environment.