Autonomic nerves are typically only hundreds of microns in diameter near their organ targets and these carry all of the sympathetic and parasympathetic control signals. We present a cuff-less microneedle array specifically designed to potentially map small autonomic nerves. The focus of this paper is the design and fabrication of an ultra-miniaturized silicon needle array on a silicone substrate. We demonstrate arrays having 25 to 100 microneedles. Each needle has a 1-micron tip and dual-taper shaft. We demonstrate an ability to control the tip shape, angle, and shaft angle which is important for balancing sharpness and stiffness. These high-density arrays also include a special backside anchor embedded in silicone for stability in the elastic substrate, yet the array freely wraps over a 300-μm nerve. Another critical method presented here is a surgical technique for inserting and securing an array without a cuff (as small as 0.3 mm wide and 1.2 mm long) by photochemical bonding of collagen/Rose Bengal adhesive agents to epineurium. Future work will focus on device functionalization and histological characterization in a rat vagus model.