3D Printed Pharmaceutical Tablet with Latent Binder Granules
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Solution Overview
Problem
3D printing of pharmaceutical tablets using loose excipient powder results in a rough surface, and food-grade binders often have high viscosity, making inkjet printing challenging, which affects the texture and aesthetics of the final product.
Innovation Solution
The use of build material granules with latent binders, pressure application, and inkjet printing of an activation solvent and active pharmaceutical ingredient formulation to produce a pharmaceutical tablet with controlled structure and surface smoothness, eliminating the need for highly viscous binders and enabling precise control over the internal distribution and density of the active ingredient.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If loose excipient powder is used as build material, then the 3D printing process can be simplified, but the surface of the printed tablet becomes rough
Solution Approach 1:
The build material is segmented into discrete granules with specific size ranges (20-400 μm) rather than using loose powder. Each granule contains excipient particles and latent binder, creating a structured building block that maintains surface smoothness while enabling layer-by-layer 3D printing.
Solution Approach 2:
The physical state of the binder is changed from liquid (affecting surface quality) to solid latent binder embedded in granules. The latent binder is activated by solvent application during printing, transforming the binding mechanism while maintaining surface smoothness and enabling inkjet compatibility.
2Stability of the object's composition
If food-grade binders are used to hold excipient powder together, then the tablet structure is stabilized, but the high viscosity makes inkjet printing challenging
Solution Approach 1:
The binder is pre-incorporated into the granule structure as a latent binder during granule fabrication. This preliminary action eliminates the need for subsequent liquid binder application, as the binding function is already embedded in the granule architecture and activated only when solvent is applied during printing.
Solution Approach 2:
A solvent acts as an intermediary to activate the latent binder within the granules. The solvent temporarily dissolves or mobilizes the latent binder, enabling particle adhesion during printing, then evaporates without remaining in the final product, avoiding viscosity issues while maintaining structural stability.
3Shape
If successive layers of material are applied in 3D printing, then three-dimensional solid parts are formed, but the process time increases
Solution Approach 1:
The granules are designed to self-bind through latent binder activation by solvent, eliminating the need for separate curing or fusion steps between layers. This continuous binding action during layer deposition reduces process time while maintaining three-dimensional structural integrity.
Solution Approach 2:
Thermal or chemical curing processes are replaced with a solvent-activated binding mechanism. The latent binder responds to solvent application by becoming active and binding particles, eliminating the need for external heat or pressure curing cycles between layers, thus reducing overall printing time.
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
This method produces pharmaceutical tablets with improved surface smoothness and controlled porosity, affecting the dissolution rate of the active ingredient, allowing for tailored release profiles and enhanced product quality.
Implementation Method 1
The activation solvent is capable of at least partially dissolving the latent binder in the pressed build material granules
Implementation Method 2
applying pressure to the build material granules, wherein the applying of the pressure to the build material granules tightens packing of the build material granules or crushes the build material granules
Implementation Method 3
utilize the first inkjet applicator to selectively dispense the activation solvent and utilize the second inkjet applicator to selectively dispense the active pharmaceutical ingredient formulation
Implementation Method 4
evaporating the activation solvent
Data Source
AI summary
In an example of a three-dimensional (3D) printing method for forming a pharmaceutical tablet, build material granules are applied. Each of the build material granules includes a plurality of excipient particles, wherein at least one of the plurality of excipient particles is a latent binder. Pressure is applied to the build material granules. An activation solvent is selectively applied on at least a portion of the pressed build material granules. An active pharmaceutical ingredient formulation including an active pharmaceutical ingredient is selectively applied on the at least the portion of the pressed build material granules. The activation solvent is evaporated.