A method of forming a microneedle array having alternating layers of material includes transforming a multilayer sheet by cutting, assembling and stretching steps to form a stretched, stacked multilayer sheet. The stretched, stacked multilayer sheet is cut, assembled and stretched to form a film, the film is heated, and at least a portion of the film is caused to be displaced into a plurality of recesses thereby forming a plurality of protrusions at a surface of the film.