Pharmaceutical Dosage Forms via Additive Carrier Printing
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Solution Overview
Problem
Current methods for producing pharmaceutical dosage forms fail to combine the advantages of classical solid or semisolid production with additive manufacturing processes, limiting the flexibility and precision in applying pharmaceutical active agents.
Innovation Solution
A method involving the use of active agent-free carrier structures in 2D or 3D printing devices, where pharmaceutical active agents are applied using additive processes such as fused filament fabrication, fused layer modeling, or binder jetting, allowing for precise three-dimensional arrangements and the inclusion of colored substances for information encoding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If classical production methods are used for solid or semisolid dosage forms, then manufacturing simplicity is maintained, but flexibility and precision in applying pharmaceutical active agents are limited
Solution Approach 1:
The production method is divided into distinct segments: first providing an active agent-free carrier structure, then separately applying pharmaceutical active agents through additive manufacturing. This segmentation allows each step to be optimized independently, achieving high precision in agent application while maintaining overall process manageability.
Solution Approach 2:
The carrier structure is prepared in advance without active agents, creating a ready-to-use base that can then receive precisely deposited pharmaceutical agents. This preliminary preparation enables the subsequent additive manufacturing step to focus solely on precise agent placement, improving manufacturing precision without proportionally increasing overall complexity.
2Adaptability or versatility
If additive manufacturing processes are used to apply active agents, then flexibility and precision are improved, but manufacturing complexity increases
Solution Approach 1:
The additive manufacturing device is designed to perform multiple functions: it can apply different pharmaceutical active agents, create various dosage form configurations, and incorporate information encoding. This multi-functionality achieves high adaptability while consolidating capabilities into a single platform, reducing the need for multiple specialized devices.
Solution Approach 2:
The method enables different regions of the carrier structure to receive different active agents or concentrations, allowing customized dosage distribution. This local quality approach provides versatility in dosage form design while using standardized additive manufacturing technology, balancing flexibility with manageable device complexity.
3Manufacturing precision
If active agents are applied onto carrier structures using conventional methods, then production speed is maintained, but precision in active agent distribution is limited
Solution Approach 1:
Conventional mechanical mixing and coating methods are replaced with additive manufacturing technology that deposits active agents layer by layer or point by point. This substitution enables precise spatial control of agent distribution while maintaining production efficiency through automated printing processes, achieving both high precision and sustained productivity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables the production of customized solid or semisolid dosage forms with precise active agent distribution and information encoding, enhancing patient safety and compliance through visible information structures, while allowing for a wide range of pharmaceutical forms and configurations.
Implementation Method 1
a binder fluid is applied to the powder layer by the printing device wherein it is also possible to apply the binder fluid suitably in pointwise or region wise fashion
Implementation Method 2
the meltable carrier substance or base substance, respectively, containing the agent or agents, is present in a different form, preferably as granules, pellets, powders or flakes, which are then printed by the per se known FLM (fused layer modelling), typically by hot melt extrusion
Implementation Method 3
the three-dimensional formation of the active agent-containing structure on the carrier is done by preferably layer wise application of single volume increments (hereinafter also denoted as 'voxels') of a fluid wherein at least part of the applied volume increments of the fluid contain the active agent(s)
Data Source
AI summary
The invention relates to a method for producing solid or semi-solid dosage forms of pharmaceutical active ingredients. According to the method, an active-ingredient-free carrier structure is arranged in a 2D or 3D printing device and at least one pharmaceutical active ingredient is applied to at least one portion of the carrier structure by way of a 2D or 3D printing method carried out by the printing device. The invention also relates to semi-solid or solid dosage forms that are producible by the method according to the invention.