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Digkas T, Porfire A, Van Renterghem J, Samaro A, Borodi G, Vervaet C, Crișan AG, Iurian S, De Beer T, Tomuta I. Development of Diclofenac Sodium 3D Printed Cylindrical and Tubular-Shaped Tablets through Hot Melt Extrusion and Fused Deposition Modelling Techniques. Pharmaceuticals (Basel) 2023; 16:1062. [PMID: 37630976 PMCID: PMC10459775 DOI: 10.3390/ph16081062] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Abstract] [Key Words] [Grants] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 06/23/2023] [Revised: 07/20/2023] [Accepted: 07/22/2023] [Indexed: 08/27/2023] Open
Abstract
The present study aimed to develop 3D printed dosage forms, using custom-made filaments loaded with diclofenac sodium (DS). The printed tablets were developed by implementing a quality by design (QbD) approach. Filaments with adequate FDM 3D printing characteristics were produced via hot melt extrusion (HME). Their formulation included DS as active substance, polyvinyl alcohol (PVA) as a polymer, different types of plasticisers (mannitol, erythritol, isomalt, maltodextrin and PEG) and superdisintegrants (crospovidone and croscarmellose sodium). The physicochemical and mechanical properties of the extruded filaments were investigated through differential scanning calorimetry (DSC), X-ray diffraction (XRD) and tensile measurements. In addition, cylindrical-shaped and tubular-shaped 3D dosage forms were printed, and their dissolution behaviour was assessed via various drug release kinetic models. DSC and XRD results demonstrated the amorphous dispersion of DS into the polymeric filaments. Moreover, the 3D printed tablets, regardless of their composition, exhibited a DS release of nearly 90% after 45 min at pH 6.8, while their release behaviour was effectively described by the Korsmeyer-Peppas model. Notably, the novel tube design, which was anticipated to increase the drug release rate, proved the opposite based on the in vitro dissolution study results. Additionally, the use of crospovidone increased DS release rate, whereas croscarmellose sodium decreased it.
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Affiliation(s)
- Tryfon Digkas
- Laboratory of Pharmaceutical Process Analytical Technology, Ghent University, Ottergemsesteenweg 460, 9000 Ghent, Belgium; (T.D.); (J.V.R.); (T.D.B.)
| | - Alina Porfire
- Department of Pharmaceutical Technology and Biopharmacy, Faculty of Pharmacy, University of Medicine and Pharmacy “Iuliu Hațieganu”, 41 Victor Babeș Street, 400012 Cluj-Napoca, Romania; (A.G.C.); (S.I.); (I.T.)
| | - Jeroen Van Renterghem
- Laboratory of Pharmaceutical Process Analytical Technology, Ghent University, Ottergemsesteenweg 460, 9000 Ghent, Belgium; (T.D.); (J.V.R.); (T.D.B.)
| | - Aseel Samaro
- Laboratory of Pharmaceutical Technology, Ghent University, Ottergemsesteenweg 460, 9000 Ghent, Belgium; (A.S.); (C.V.)
| | - Gheorghe Borodi
- National Institute for Research and Development of Isotopic and Molecular Technologies, 65-103 Donath Street, 400293 Cluj-Napoca, Romania;
| | - Chris Vervaet
- Laboratory of Pharmaceutical Technology, Ghent University, Ottergemsesteenweg 460, 9000 Ghent, Belgium; (A.S.); (C.V.)
| | - Andrea Gabriela Crișan
- Department of Pharmaceutical Technology and Biopharmacy, Faculty of Pharmacy, University of Medicine and Pharmacy “Iuliu Hațieganu”, 41 Victor Babeș Street, 400012 Cluj-Napoca, Romania; (A.G.C.); (S.I.); (I.T.)
| | - Sonia Iurian
- Department of Pharmaceutical Technology and Biopharmacy, Faculty of Pharmacy, University of Medicine and Pharmacy “Iuliu Hațieganu”, 41 Victor Babeș Street, 400012 Cluj-Napoca, Romania; (A.G.C.); (S.I.); (I.T.)
| | - Thomas De Beer
- Laboratory of Pharmaceutical Process Analytical Technology, Ghent University, Ottergemsesteenweg 460, 9000 Ghent, Belgium; (T.D.); (J.V.R.); (T.D.B.)
| | - Ioan Tomuta
- Department of Pharmaceutical Technology and Biopharmacy, Faculty of Pharmacy, University of Medicine and Pharmacy “Iuliu Hațieganu”, 41 Victor Babeș Street, 400012 Cluj-Napoca, Romania; (A.G.C.); (S.I.); (I.T.)
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Samaro A, Vergaelen M, Purino M, Tigrine A, de la Rosa VR, Goudarzi NM, Boone MN, Vanhoorne V, Hoogenboom R, Vervaet C. Poly(2-alkyl-2-oxazoline)s: A polymer platform to sustain the release from tablets with a high drug loading. Mater Today Bio 2022; 16:100414. [PMID: 36133793 PMCID: PMC9483731 DOI: 10.1016/j.mtbio.2022.100414] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 04/18/2022] [Revised: 08/24/2022] [Accepted: 08/28/2022] [Indexed: 11/25/2022] Open
Abstract
Sustaining the release of highly dosed APIs from a matrix tablet is challenging. To address this challenge, this study evaluated the performance of thermoplastic poly (2-alkyl-2-oxazoline)s (PAOx) as matrix excipient to produce sustained-release tablets via three processing routes: (a) hot-melt extrusion (HME) combined with injection molding (IM), (b) HME combined with milling and compression and (c) direct compression (DC). Different PAOx (co-)polymers and polymer mixtures were processed with several active pharmaceutical ingredients having different aqueous solubilities and melting temperatures (metoprolol tartrate (MPT), metformin hydrochloride (MTF) and theophylline anhydrous (THA)). Different PAOx grades were synthesized and purified by the Supramolecular Chemistry Group, and the effect of PAOx grade and processing technique on the in vitro release kinetics was evaluated. Using the hydrophobic poly (2-n-propyl-2-oxazoline) (PnPrOx) as a matrix excipient allowed to sustain the release of different APIs, even at a 70% (w/w) drug load. Whereas complete THA release was not achieved from the PnPrOx matrix over 24 h regardless of the processing technique, adding 7.5% w/w of the hydrophilic poly (2-ethyl-2-oxazoline) to the hydrophobic PnPrOx matrix significantly increased THA release, highlighting the relevance of mixing different PAOx grades. In addition, it was demonstrated that the release of THA was similar from co-polymer and polymer mixtures with the same polymer ratios. On the other hand, as the release of MTF from a PnPrOx matrix was fast, the more hydrophobic poly (2-sec-butyl-2-oxazoline) (PsecBuOx) was used to retard MTF release. In addition, a mixture between the hydrophilic PEtOx and the hydrophobic PsecBuOx allowed accurate tuning of the release of MTF formulations. Finally, it was demonstrated that PAOx also showed a high ability to tune the in vivo release. IM tablets containing 70% MTF and 30% PsecBuOx showed a lower in vivo bioavailability compared to IM tablets containing a low PEtOx concentration (7.5%, w/w) in combination with PsecBuOx (22.5%, w/w). Importantly, the in vivo MTF blood level from the sustained release tablets correlated well with the in vitro release profiles. In general, this work demonstrates that PAOx polymers offer a versatile formulation platform to adjust the release rate of different APIs, enabling sustained release from tablets with up to 70% w/w drug loading.
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Affiliation(s)
- Aseel Samaro
- Laboratory of Pharmaceutical Technology, Ghent University, Ottergemsesteenweg, 460 9000, Ghent, Belgium
| | - Maarten Vergaelen
- Supramolecular Chemistry Group, Centre of Macromolecular Chemistry (CMaC), Department of Organic and Macromolecular Chemistry, Krijgslaan 281-S4 9000 Ghent University, Ghent, Belgium
| | - Martin Purino
- Supramolecular Chemistry Group, Centre of Macromolecular Chemistry (CMaC), Department of Organic and Macromolecular Chemistry, Krijgslaan 281-S4 9000 Ghent University, Ghent, Belgium
| | - Ali Tigrine
- Supramolecular Chemistry Group, Centre of Macromolecular Chemistry (CMaC), Department of Organic and Macromolecular Chemistry, Krijgslaan 281-S4 9000 Ghent University, Ghent, Belgium
| | - Victor R de la Rosa
- Supramolecular Chemistry Group, Centre of Macromolecular Chemistry (CMaC), Department of Organic and Macromolecular Chemistry, Krijgslaan 281-S4 9000 Ghent University, Ghent, Belgium.,Avroxa BV., Technologiepark-Zwijnaarde, Ghent, Belgium
| | - Niloofar Moazami Goudarzi
- Radiation Physics Research Group, Department of Physics and Astronomy, Ghent University, Belgium.,Center for X-ray Tomography (UGCT), Ghent University, Ghent, Belgium
| | - Matthieu N Boone
- Radiation Physics Research Group, Department of Physics and Astronomy, Ghent University, Belgium.,Center for X-ray Tomography (UGCT), Ghent University, Ghent, Belgium
| | - Valérie Vanhoorne
- Laboratory of Pharmaceutical Technology, Ghent University, Ottergemsesteenweg, 460 9000, Ghent, Belgium
| | - Richard Hoogenboom
- Supramolecular Chemistry Group, Centre of Macromolecular Chemistry (CMaC), Department of Organic and Macromolecular Chemistry, Krijgslaan 281-S4 9000 Ghent University, Ghent, Belgium
| | - Chris Vervaet
- Laboratory of Pharmaceutical Technology, Ghent University, Ottergemsesteenweg, 460 9000, Ghent, Belgium
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Moazami Goudarzi N, Samaro A, Vervaet C, Boone MN. Development of Flow-Through Cell Dissolution Method for In Situ Visualization of Dissolution Processes in Solid Dosage Forms Using X-ray μCT. Pharmaceutics 2022; 14:pharmaceutics14112475. [PMID: 36432667 PMCID: PMC9696340 DOI: 10.3390/pharmaceutics14112475] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Abstract] [Key Words] [Track Full Text] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 10/18/2022] [Revised: 11/08/2022] [Accepted: 11/10/2022] [Indexed: 11/19/2022] Open
Abstract
Visualization of the dynamic behavior of pharmaceutical dosage forms during the dissolution process offers a better understanding of the drug release mechanism, enabling the design of customized dosage forms. In this study, an X-ray tomography-based approach is proposed to monitor and analyze the dynamics of the structure at the pore scale level during the dissolution process. A flow-through cell dissolution apparatus was developed, capable of mimicking the standard in vitro dissolution process, which can be easily positioned in an X-ray tomography setup. The method was utilized to study the dissolution of a Capa® (polycaprolactone)-based sustained-release 3D printed tablet. The impact of the flow rate on the active pharmaceutical ingredient (API) release rate was studied and 16 mL/min was selected as a suitable flow rate. Furthermore, cesium chloride (CsCl) was used as a contrast agent to increase the contrast between the sample and the dissolution medium. Data obtained with this novel technique were in a good agreement with the released drug rate acquired by the standard in vitro dissolution test (the similarity factor (f2) = 77%). Finally, the proposed approach allowed visualizing the internal structure of the sample, as well as real-time tracking of solution ingress into the product.
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Affiliation(s)
- Niloofar Moazami Goudarzi
- Department of Physics and Astronomy, Radiation Physics, Ghent University, Proeftuinstraat 86/N12, 9000 Gent, Belgium
- Centre for X-ray Tomography (UGCT), Ghent University, Proeftuinstraat 86, 9000 Gent, Belgium
- Correspondence: (N.M.G.); (M.N.B.)
| | - Aseel Samaro
- Laboratory of Pharmaceutical Technology, Department of Pharmaceutics, Ghent University, Ottergemsesteenweg 460, 9000 Gent, Belgium
| | - Chris Vervaet
- Laboratory of Pharmaceutical Technology, Department of Pharmaceutics, Ghent University, Ottergemsesteenweg 460, 9000 Gent, Belgium
| | - Matthieu N. Boone
- Department of Physics and Astronomy, Radiation Physics, Ghent University, Proeftuinstraat 86/N12, 9000 Gent, Belgium
- Centre for X-ray Tomography (UGCT), Ghent University, Proeftuinstraat 86, 9000 Gent, Belgium
- Correspondence: (N.M.G.); (M.N.B.)
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Samaro A, Shaqour B, Goudarzi NM, Ghijs M, Cardon L, Boone MN, Verleije B, Beyers K, Vanhoorne V, Cos P, Vervaet C. Can filaments, pellets and powder be used as feedstock to produce highly drug-loaded ethylene-vinyl acetate 3D printed tablets using extrusion-based additive manufacturing? Int J Pharm 2021; 607:120922. [PMID: 34303815 DOI: 10.1016/j.ijpharm.2021.120922] [Citation(s) in RCA: 7] [Impact Index Per Article: 2.3] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 06/11/2021] [Revised: 07/17/2021] [Accepted: 07/19/2021] [Indexed: 02/07/2023]
Abstract
Personalized medicine, produced through 3D printing, is a promising approach for delivering the required drug dose based on the patient's profile. The primary purpose of this study was to investigate the potential of two different extrusion-based additive manufacturing techniques - fused filament fabrication (FFF) and screw-based 3D printing, also known as direct extrusion additive manufacturing (DEAM). Different ethylene-vinyl acetate (EVA) copolymers (9 %VA, 12 %VA, 16 %VA, 18 %VA, 25 %VA, 28 %VA, and 40 %VA) were selected and loaded with 50% (w/w) metoprolol tartrate (MPT). Hot-melt extrusion was performed to produce the drug-loaded filaments. These filaments were used for FFF in which the mechanical and rheological properties were rate-limiting steps. The drug-loaded filament based on the 18 %VA polymer was the only printable formulation due to its appropriate mechanical and rheological properties. As for the highest VA content (40 %VA), the feeding pinch rolls cause buckling of the filaments due to insufficient stiffness, while other filaments were successfully feedable towards the extrusion nozzle. However, poor flowability out of the extrusion nozzle due to the rheological limitation excluded these formulations from the initial printing trials. Filaments were also pelletized and used for pellets-DEAM. This method showed freedom in formulation selection because the screw rotation drives the material flow with less dependence on their mechanical properties. All drug-loaded pellets were successfully printed via DEAM, as sufficient pressure was built up towards the nozzle due to single screw extrusion processing method. In contrast, filaments were used as a piston to build up the pressure required for extrusion in filament-based printing, which highly depends on the filament's mechanical properties. Moreover, printing trials using a physical mixture in powder form were also investigated and showed promising results. In vitro drug release showed similar release patterns for MPT-loaded 3D printed tablets regardless of the printing technique. Additionally, pellets-DEAM enabled the production of tablets with the highest VA content, which failed in FFF 3D printing but showed an interesting delayed release profile.
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Affiliation(s)
- Aseel Samaro
- Laboratory of Pharmaceutical Technology, Faculty of Pharmaceutical Sciences, Ghent University, Ghent, Belgium; Pharmacy Department, Faculty of Pharmacy, Nursing and Health Professions, Birzeit University, Palestine
| | - Bahaa Shaqour
- Laboratory for Microbiology, Parasitology and Hygiene (LMPH), Faculty of Pharmaceutical, Biomedical and Veterinary Sciences, University of Antwerp, Belgium; Mechanical and Mechatronics Engineering Department, Faculty of Engineering & Information Technology, An-Najah National University, Palestine
| | - Niloofar Moazami Goudarzi
- Radiation Physics-Centre for X-ray Tomography, Department of Physics and Astronomy, Ghent University, Belgium
| | - Michael Ghijs
- Laboratory of Pharmaceutical Process Analytical Technology, Faculty of Pharmaceutical Sciences, Ghent University, Belgium
| | - Ludwig Cardon
- Centre for Polymer and Material Technologies (CPMT), Department of Materials, Textiles and Chemical Engineering, Ghent University, Belgium
| | - Matthieu N Boone
- Radiation Physics-Centre for X-ray Tomography, Department of Physics and Astronomy, Ghent University, Belgium
| | | | | | - Valérie Vanhoorne
- Laboratory of Pharmaceutical Technology, Faculty of Pharmaceutical Sciences, Ghent University, Ghent, Belgium
| | - Paul Cos
- Laboratory for Microbiology, Parasitology and Hygiene (LMPH), Faculty of Pharmaceutical, Biomedical and Veterinary Sciences, University of Antwerp, Belgium
| | - Chris Vervaet
- Laboratory of Pharmaceutical Technology, Faculty of Pharmaceutical Sciences, Ghent University, Ghent, Belgium.
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Henry S, Samaro A, Marchesini FH, Shaqour B, Macedo J, Vanhoorne V, Vervaet C. Extrusion-based 3D printing of oral solid dosage forms: Material requirements and equipment dependencies. Int J Pharm 2021; 598:120361. [PMID: 33571622 DOI: 10.1016/j.ijpharm.2021.120361] [Citation(s) in RCA: 21] [Impact Index Per Article: 7.0] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 12/09/2020] [Revised: 02/01/2021] [Accepted: 02/03/2021] [Indexed: 02/08/2023]
Abstract
Extrusion-based 3D printing is steadily gaining importance as a manufacturing technique due to its flexibility and wide range of possible end-products. In the medical field, the technique is being exploited for a variety of applications and one of these is the production of personalised medicines. However, despite many proof-of-concept studies, more thorough insights in the production technique itself and the required material properties are needed before 3D printing can be fully exploited in a hospital or pharmacy setting. This research aims at clarifying the complex interplay between material properties, process parameters and printer-dependent variables. A variety of different polymers and polymer-drug blends were extruded (diameter 1.75±0.05 mm) and characterised in terms of mechanical, thermal and rheological properties. These properties, together with the processing temperature, printing speeds and different nozzle diameters of the 3D printer were linked to the quality of the end-product. Different failure mechanisms (mechanical, thermal) were assessed. Decisive material parameters (e.g. cross-over point) for optimal printing behaviour and the importance of printer construction (nozzle diameter) were clarified. In general, this study offers insight into the 3D printing process and will help to speed up future pharmaceutical formulation development for printlets.
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Affiliation(s)
- S Henry
- Laboratory of Pharmaceutical Technology, Ghent University, 9000 Ghent, Belgium
| | - A Samaro
- Laboratory of Pharmaceutical Technology, Ghent University, 9000 Ghent, Belgium
| | - F H Marchesini
- Department of Materials, Textiles and Chemical Engineering, Ghent University, 9052 Zwijnaarde, Belgium
| | - B Shaqour
- Voxdale bv, Bijkhoevelaan 32C, 2110 Wijnegem, Belgium; Laboratory for Microbiology, Parasitology and Hygiene (LMPH), Faculty of Pharmaceutical, Biomedical and Veterinary Sciences, University of Antwerp, Universiteitsplein 1 S.7, 2610 Antwerp, Belgium
| | - J Macedo
- iMed.ULisboa, Faculdade de Farmácia, Universidade de Lisboa, Lisboa, Portugal
| | - V Vanhoorne
- Laboratory of Pharmaceutical Technology, Ghent University, 9000 Ghent, Belgium
| | - C Vervaet
- Laboratory of Pharmaceutical Technology, Ghent University, 9000 Ghent, Belgium.
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Macedo J, Samaro A, Vanhoorne V, Vervaet C, Pinto JF. Processability of poly(vinyl alcohol) Based Filaments With Paracetamol Prepared by Hot-Melt Extrusion for Additive Manufacturing. J Pharm Sci 2020; 109:3636-3644. [DOI: 10.1016/j.xphs.2020.09.016] [Citation(s) in RCA: 11] [Impact Index Per Article: 2.8] [Reference Citation Analysis] [What about the content of this article? (0)] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 05/21/2020] [Revised: 08/31/2020] [Accepted: 09/10/2020] [Indexed: 01/04/2023]
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