Pharmaceutical Granules for 3D Printing Flowability
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Solution Overview
Problem
The challenge in pharmaceutical 3D printing lies in processing pharmaceutical dosage forms with multiple components, which often results in manufacturing issues such as print failure, nonuniformity of drug content, and variability in weight and performance due to the complexity of achieving excellent flow characteristics in powders containing active pharmaceutical ingredients and processing aids.
Innovation Solution
The development of pharmaceutical compositions comprising an active pharmaceutical ingredient, a first absorbent, a second absorbent, and a surfactant, with specific formulations and processing methods to create free-flowing granules suitable for additive manufacturing, including extrusion processes and formulations that ensure high flowability, uniformity, and stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If pharmaceutical dosage forms with multiple components are processed for 3D printing, then the drug content uniformity can be improved, but the flow characteristics deteriorate leading to print failure
Solution Approach 1:
A flow promoter is introduced as an intermediary substance to mediate between the multi-component pharmaceutical formulation and the 3D printing process. The flow promoter coating on granule surfaces reduces inter-particle friction and improves flow characteristics without compromising drug content uniformity, thereby resolving the contradiction between manufacturing precision and ease of operation
Solution Approach 2:
The physical and chemical parameters of the pharmaceutical granules are modified through surface coating with flow promoter and controlled granulation processes. This changes surface properties such as roughness, charge, and moisture content, which directly improve flow characteristics while maintaining the internal composition and drug content uniformity required for manufacturing precision
2Ease of manufacture
If multiple processing aids are added to pharmaceutical formulations for 3D printing, then the manufacturability is improved, but the process complexity increases
Solution Approach 1:
The flow promoter serves multiple functions simultaneously: it improves flow characteristics, prevents static charge accumulation, reduces inter-particle adhesion, and facilitates uniform coating during 3D printing. This multi-functionality reduces the need for multiple separate processing aids, thereby improving manufacturability while controlling process complexity
Solution Approach 2:
The flow promoter is pre-applied to granule surfaces before the 3D printing process through coating or blending operations. This preliminary action ensures that the granules are pre-conditioned for optimal flow and printing performance, simplifying the overall manufacturing process by eliminating the need for complex in-process adjustments
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
The resulting pharmaceutical compositions exhibit excellent flowability, high drug content uniformity, and stability, enabling their effective use in additive manufacturing techniques like selective laser sintering for producing consistent and reliable 3D printed pharmaceutical products.
Implementation Method 1
pharmaceutical compositions comprising: (A) an active pharmaceutical ingredient: (B) a first absorbent: (C) a second absorbent
Implementation Method 2
Platforms operating on this mechanism include Selective laser Sintering (SLS) based 3D printing
Data Source
AI summary
The present disclosure provides pharmaceutical compositions which exhibit improved flowability as measured by the angle of repose. The pharmaceutical compositions comprise an active pharmaceutical ingredient, two or more absorbents, and optionally surfactant. These pharmaceutical compositions may be used in the manufacturing of pharmaceutical dosage forms or an additive manufacturing process such as 3D selective laser sintering printing.