Inkjet printing for pharmaceutics - A review of research and manufacturing.

Global regulatory, manufacturing and consumer trends are driving a need for change in current pharmaceutical sector business models, with a specific focus on the inherently expensive research costs, high-risk capital-intensive scale-up and the traditional centralised batch manufacturing paradigm. New technologies, such as inkjet printing, are being explored to radically transform pharmaceutical production processing and the end-to-end supply chain. This review provides a brief summary of inkjet printing technologies and their current applications in manufacturing before examining the business context driving the exploration of inkjet printing in the pharmaceutical sector. We then examine the trends reported in the literature for pharmaceutical printing, followed by the scientific considerations and challenges facing the adoption of this technology. We demonstrate that research activities are highly diverse, targeting a broad range of pharmaceutical types and printing systems. To mitigate this complexity we show that by categorising findings in terms of targeted business models and Active Pharmaceutical Ingredient (API) chemistry we have a more coherent approach to comparing research findings and can drive efficient translation of a chosen drug to inkjet manufacturing.

Development of high-throughput glass inkjet devices for pharmaceutical applications.

The application of the inkjet method to pharmaceutical products is promising. To make this realistic, not only does the throughput of this method need to be increased, but also the components should be inert to pharmaceutical preparations. We present designs of glass-based inkjet devices that are capable of producing droplets at high rates. To achieve this, inkjet devices from glass capillary tubes were manufactured with orifice diameters of 5, 10 and 20 µm and were actuated with diaphragm piezoelectric disks. Also, a pressure capsule was formed by creating a manifold at a distance from the orifice tip. Placing the piezoelectric disk at 0.5 mm distance from the tip allowed the formation of a jet at 3.2 MHz in certain designs, but for a short period of time because of overheating. The length of the pressure capsule, its inlet diameter, and the nozzle tip geometry were crucial to lower the required power. Actuating an inkjet device with 10 µm orifice diameter comfortably at 900 kHz and drying the droplets from 1% salbutamol sulphate solution allowed the formation of particles with diameters of 1.76 ± 0.15 µm and the geometric standard deviation of 1.08. In conclusion, optimising internal design of glass inkjet devices allowed the production of high-throughput droplet ejectors.

Printing stable liquid tracks on a surface with finite receding contact angle.

We have used high-speed imaging to study the formation of liquid tracks on a surface with nonzero receding contact angle, by the sequential deposition of liquid drops. For small drop spacing we found good agreement with the track morphology predicted by an existing line stability model. In addition, we confirmed definitively the preferential drop-to-bead fluid flow and the predicted drop spreading variation in the scalloped line and paired bead formation regimes. However, we found that without accounting for drop impact inertia, the model underestimated the maximum drop spreading radii and, hence, the instantaneous track width. In addition, the printed track became stable at larger drop spacing, in contrast to the expected behavior. We believe that the destabilizing effect of a receding contact line may be minimized when track radii, as predicted by volume conservation and drop-bead coalescence dynamics, converge as the drop spacing increases. An increase in viscous dissipation and a reduction of the capillary-driven flow may be the additional stabilization mechanisms. The latter may also be responsible for achieving a stable and symmetrical track when printing with a shorter interval (higher print frequency) at a given drop spacing.