Hot melt extruded PLGA implants loaded with ibuprofen: How heat exposure alters the physical drug state

PLGA Implants for Controlled Drug Delivery and Regenerative Medicine: Advances, Challenges, and Clinical Potential

Poly(lactide-co-glycolide) (PLGA) implants have become a cornerstone in drug delivery and regenerative medicine due to their biocompatibility, tunable degradation, and capacity for sustained, localized therapeutic release. Recent innovations in polymer design, fabrication methods, and functional modifications have expanded their utility across diverse clinical domains, including oncology, neurology, orthopedics, and ophthalmology. This review provides a comprehensive analysis of PLGA implant properties, fabrication strategies, and biomedical applications, while addressing key challenges such as burst release, incomplete drug release, manufacturing complexity, and inflammatory responses. Emerging solutions-such as 3D printing, in situ forming systems, predictive modeling, and patient-specific customization-are improving implant performance and clinical translation. Emphasis is placed on scalable production, long-term biocompatibility, and personalized design to support the next generation of precision therapeutics.

Investigation of the Thermal Stability and Hydrolytic Degradation Kinetics of Poly(Lactide-co-Glycolide) Melts

Poly(lactide-co-glycolide) (PLGA) is widely used in a variety of long-acting injectables. However, its biodegradable nature creates potential chemical stability challenges during melt extrusion, where PLGA is exposed to elevated temperature (100-140 °C) for several minutes. This study evaluated the thermal stability of three PLGA grades (Resomer® 502, 502H, and 505) with varying molecular weights and chain-ends using a differential scanning calorimeter and twin-screw extruder. DSC results revealed that both residual water content and chain-end groups significantly accelerate PLGA degradation. At 0.2% water content, all samples maintained good stability (less than 15% reduction in molecular weight). However, at 0.4% water content, Resomer 502H, which has acid end groups, experienced significant degradation (45% reduction in molecular weight) after 30 min at 140 °C due to catalyzed hydrolysis. The extruded samples remained stable across tested barrel temperatures (100 °C and 140 °C) and screw speeds (125 and 250 rpm). Further investigations of PLGA with 0.2% water content demonstrates that the hydrolysis rates of Resomer® 502 and 505 were comparable, indicating that molecular weight does not influence hydrolysis rate. In contrast, Resomer® 502H exhibited a higher hydrolysis rate and a slightly higher activation energy, suggesting a greater temperature dependency. Additionally, when subjected to 200 °C for one hour with less than 0.03% water content, Resomer® 505 showed a less than 7% reduction in molecular weight, indicating minimal thermal degradation. Conversely, Resomer® 502 and 502H experienced an increase in molecular weight, which was likely attributed to recombination reactions, particularly in Resomer® 502H, which has higher tin content (170 ppm).

Mechanistic Model for Drug Release from PLGA-Based Biodegradable Implants for In Vitro Release Testing: Development and Validation

Several factors can affect drug release from polylactide coglycolide (PLGA)-based formulations, including polymer and drug properties, formulation components, manufacturing processes, and environmental in vitro or in vivo conditions. To achieve optimal release profiles for specific drug delivery applications, it is crucial to understand the mechanistic processes that determine drug release from PLGA-based formulations. In the current study, we developed a mechanistic model for the in vitro drug release of PLGA-based solid implants. The model accounts for all known critical quality attributes (CQAs) and considers the most important release rate processes, including water or dissolution medium influx into the porous structure of the implant, initial noncatalytic hydrolysis of PLGA, autocatalytic hydrolysis, dissolution of oligomers and monomers into the aqueous medium, the liberation of the trapped solid drug from the polymer matrix, dissolution of the solid drug into the wetted pore network, diffusion of the dissolved drug out of the implant, and distribution of the dissolved drug into the dissolution medium. The model has been validated using in vitro release data obtained from implants of four drugs (buserelin, afamelanotide, brimonidine, and nafarelin). The model presented in this manuscript provides valuable insights into the kinetics and mechanism of drug release from PLGA-based solid implants and has demonstrated the potential for optimizing formulation design. The in vitro release model, coupled with physiologically based pharmacokinetic (PBPK) modeling, can predict the in vivo performance of implants and can be used to support bioequivalence studies in a drug development program.

Optimization of 3D Printing Parameters of Polylactic-Co-Glycolic Acid-Based Biodegradable Antibacterial Materials Using Fused Deposition Modeling

A high incidence of ureteral diseases was needed to find better treatments such as implanting ureteral stents. The existing ureteral stents produced a series of complications such as bacterial infection and biofilm after implantation. The fused deposition modeling (FDM) of 3D printing biodegradable antibacterial ureteral stents had gradually become the trend of clinical treatment. But it was necessary to optimize the FDM 3D printing parameters of biodegradable bacteriostatic materials to improve the precision and performance of manufacturing. In this study, polylactic-co-glycolic acid (PLGA), polycaprolactone (PCL), and nanosilver (AgNP) were mixed by the physical blending method, and the 3D printing parameters and properties were studied. The relationship between printing parameters and printing errors was obtained by single-factor variable method and linear fitting. The performance of 3D printing samples was obtained through infrared spectrum detection, molecular weight detection, and mechanical testing. The printing temperature and the printing pressure were proportional to the printing error, and the printing speed was inversely proportional to the printing error. The 3D printing has little effect on the functional groups and molecular weights of biodegradable antibacterial materials. The addition of AgNP increases the compressive strength and breaking strength by 8.332% and 37.726%, which provided ideas for regulating the mechanical properties. The parameter range of biodegradable bacteriostatic materials for thermal melting 3D printing was precisely established by optimizing the parameters of printing temperature, printing pressure, and printing speed, which would be further applied to the advanced manufacturing of biodegradable implant interventional medical devices.

Role of PLGA Variability in Controlled Drug Release from Dexamethasone Intravitreal Implants

Long-acting injectable formulations based on poly(lactide-co-glycolide) (PLGA) have been commercialized for over 30 years in at least 20 FDA-approved products. These formulations offer several advantages, including reduced dosing frequency, improved patient compliance, and maintenance of therapeutic levels of drug. Despite extensive studies, the inherent complexity of the PLGA copolymer still poses significant challenges associated with the development of generic formulations having drug release profiles equivalent to those of the reference listed drugs. In addition, small changes to PLGA physicochemical properties or the drug product manufacturing process can have a major impact on the drug release profile of these long-acting formulations. This work seeks to better understand how variability in the physicochemical properties of similar PLGAs affects drug release from PLGA solid implants using Ozurdex (dexamethasone intravitreal implant) as the model system. Four 50:50, acid-terminated PLGAs of similar molecular weights were used to prepare four dexamethasone intravitreal implants structurally equivalent to Ozurdex. The PLGAs were extensively characterized by using a variety of analytical techniques prior to implant manufacture using a continuous, hot-melt extrusion process. In vitro release testing of the four structurally equivalent implants was performed in both normal saline and phosphate-buffered saline (PBS), yielding drastically different results between the two methods. In normal saline, no differences in the release profiles were observed. In PBS, the drug release profiles were sensitive to small changes in the residual monomer content, carboxylic acid end group content, and blockiness of the polymers. This finding further underscores the need for a physiologically relevant in vitro release testing method as part of a robust quality control strategy for PLGA-based solid implant formulations.

3D printed PLGA implants: How the filling density affects drug release

Different types of ibuprofen-loaded, poly (D,L lactic-co-glycolic acid) (PLGA)-based implants were prepared by 3D printing (Droplet Deposition Modeling). The theoretical filling density of the mesh-shaped implants was varied from 10 to 100%. Drug release was measured in agarose gels and in well agitated phosphate buffer pH 7.4. The key properties of the implants (and dynamic changes thereof upon exposure to the release media) were monitored using gravimetric measurements, optical microscopy, Differential Scanning Calorimetry, Gel Permeation Chromatography, and Scanning Electron Microscopy. Interestingly, drug release was similar for implants with 10 and 30% filling density, irrespective of the experimental set-up. In contrast, implants with 100% filling density showed slower release kinetics, and the shape of the release curve was altered in agarose gels. These observations could be explained by the existence (or absence) of a continuous aqueous phase between the polymeric filaments and the "orchestrating role" of substantial system swelling for the control of drug release. At lower filling densities, it is sufficient for the drug to be released from a single filament. In contrast, at high filling densities, the ensemble of filaments acts as a much larger (more or less homogeneous) polymeric matrix, and the average diffusion pathway to be overcome by the drug is much longer. Agarose gel (mimicking living tissue) hinders substantial PLGA swelling and delays the onset of the final rapid drug release phase. This improved mechanistic understanding of the control of drug release from PLGA-based 3D printed implants can help to facilitate the optimization of this type of advanced drug delivery systems.

Degradation behavior of 2D auxetic structure with biodegradable polymer under mechanical stress

Coronary heart disease is serious harm to human health. Vascular scaffold implantation is the main treatment. Biodegradable polymers are widely used in vascular scaffolds for good biodegradability and biocompatibility. However, whether the mechanical properties and radial expansion ability can successfully implant the scaffold without acute elastic retraction remains to be further studied. Because of the unique deformation mechanism, shear resistance, and resilience, auxetic structures can effectively avoid the restenosis of degraded vascular scaffolds. Firstly, the plane isotropic and plane anisotropic auxetic structural scaffolds were designed. The control structures (traditional structures) scaffolds were taken as the contrast. PCL was used to prepare the vascular auxetic by 3D printing. The printing parameters of fused deposition 3D printing, such as printing temperature, printing speed, and printing pressure, were studied to determine the optimal printing parameters of PCL. A self-assembled cyclic tensile stress loading device was used to investigate the degradation behavior of different scaffolds under different sizes of cyclic tensile stress, such as surface morphology, pH changes, mass loss rate, and mechanical properties. The increase of stress, surface roughness, and mass loss rate of the scaffolds all showed an increasing trend. pH gradually decreased from the fifth week, and the decrease was proportional to the stress. A large level of stress loading intensifies the decline of elastic modulus and the ultimate strength of the scaffold. In conclusion, the increase of periodic tensile stress will accelerate the degradation of scaffolds, and the degradation behavior of scaffolds with different configurations is different. The degradation rate of dilatant scaffolds was higher than that of control scaffolds, and the degradation rate of anisotropic auxetic scaffolds was higher than that of isotropic auxetic scaffolds, which provides a theoretical reference for the application of auxetic structure in the degradation of vascular scaffolds.

Drug release mechanisms of high-drug-load, melt-extruded dexamethasone intravitreal implants

Ozurdex is an FDA-approved sustained-release, biodegradable implant formulated to deliver the corticosteroid dexamethasone to the posterior segment of the eye for up to 6 months. Hot-melt extrusion is used to prepare the 0.46 mm × 6 mm, rod-shaped implant by embedding the drug in a matrix of poly(lactic-co-glycolic acid) (PLGA) in a 60:40 drug:polymer ratio by weight. In our previous work, the Ozurdex implant was carefully studied and reverse engineered to produce a compositionally and structurally equivalent implant for further analysis. In this work, the reverse-engineered implant is thoroughly characterized throughout the in vitro dissolution process to elucidate the mechanisms of controlled drug release. The implant exhibits a triphasic release profile in 37 °C normal saline with a small burst release (1-2 %), a one-week lag phase with limited release (less than10 %), and a final phase where the remainder of the dose is released over 3-4 weeks. The limited intermolecular interaction between dexamethasone and PLGA renders the breakdown of the polymer the dominating mechanism of controlled release. A close relationship between drug release and total implant mass loss was observed. Unique chemical and structural differences were seen between the core of the implant and the implant surface driven by diffusional limitations, autocatalytic hydrolysis, and osmotic effects.

Reverse engineering the Ozurdex dexamethasone intravitreal implant

Ozurdex is a biodegradable implant formulated for sustained-release delivery of the corticosteroid dexamethasone to the posterior segment of the eye. The small, rod-shaped implant is administered directly to the vitreous using a dedicated applicator, and releases drug for up to 6 months after administration. Sustained release is achieved by embedding dexamethasone in a matrix of 50:50 poly(lactic-co-glycolic acid) (PLGA). In this work, the Ozurdex implant was thoroughly characterized to enable the reverse engineering of a compositionally and structurally equivalent implant. Advanced imaging techniques such as scanning electron microscopy (SEM) and microcomputed tomography (microCT) revealed that the Ozurdex implant exhibits an irregular surface and an internal porosity of 6% due to a large number of discrete voids approximately 3 μm in diameter. Thermal and spectroscopic analyses showed limited interaction between the drug and the polymer, resulting in a two-phase system of dexamethasone crystals embedded within a PLGA matrix. Reverse-engineered implants with properties similar to Ozurdex were prepared using a two-step hot-melt extrusion process. The reverse-engineered implants exhibited a triphasic drug release profile similar to Ozurdex. This work seeks to provide insight into the manufacturing process and characterization of PLGA-based solid implants to support future generic product development.

PLGA implants for controlled drug release: Impact of the diameter

The aim of this study was to better understand the importance of the diameter of poly(lactic-co-glycolic acid) (PLGA)-based implants on system performance, in particular the control of drug release. Different types of ibuprofen-loaded implants were prepared by hot melt extrusion using a Leistritz Nano 16 twin-screw extruder. Drug release was measured in well agitated phosphate buffer pH7.4 bulk fluid and in agarose gels in Eppendorf tubes or transwell plates. Dynamic changes in the implants' dry & wet mass, volume, polymer molecular weight as well as inner & outer morphology were monitored using gravimetric analysis, optical macroscopy, gel permeation chromatography and scanning electron microscopy. The physical states of the drug and polymer were determined by DSC. Also pH changes in the release medium were investigated. Irrespective of the type of experimental set-up, the resulting absolute and relative drug release rates decreased with increasing implant diameter (0.7 to 2.8 mm). Bi-phasic drug release was observed in all cases from the monolithic solutions (ibuprofen was dissolved in the polymer): A zero order release phase was followed by a final, rapid drug release phase (accounting for 80-90% of the total drug dose). The decrease in the relative drug release rate with increasing system diameter can be explained by the increase in the diffusion pathway lengths to be overcome. Interestingly, also the onset of the final rapid drug release phase was delayed with increasing implant diameter. This can probably be attributed to the higher mechanical stability of thicker devices, offering more resistance to substantial entire system swelling.