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Selective laser sintering (SLS) is an emerging threedimensional (3D) printing technology that uses a laser to fuse powder particles together, which allows the fabrication of personalized solid dosage forms. It possesses great potential for commercial use. However, a major drawback of SLS is the need to heat the powder bed while printing; this leads to high energy consumption (and hence a large carbon footprint), which may hinder its translation to industry. In this study, the concept of cold laser sintering (CLS) is introduced. In CLS, the aim is to sinter particles without heating the powder bed, where the energy from the laser, alone, is sufficient to fuse adjacent particles. The study demonstrated that a laser power above 1.8 W was sufficient to sinter both KollicoatIR and Eudragit L100-55-based formulations at room temperature. The cold sintering printing process was found to reduce carbon emissions by 99% compared to a commercial SLS printer. The CLS printed formulations possessed characteristics comparable to those made with conventional SLS printing, including a porous microstructure, fast disintegration time, and molecular dispersion of the drug. It was also possible to achieve higher drug loadings than was possible with conventional SLS printing. Increasing the laser power from 1.8 to 3.0 W increased the flexural strength of the printed formulations from 0.6 to 1.6 MPa, concomitantly increasing the disintegration time from 5 to over 300 s. CLS appears to offer a new route to laser-sintered pharmaceuticals that minimizes impact on the environment and is fit for purpose in Industry 5.0.
Selective laser sintering (SLS) is an emerging threedimensional (3D) printing technology that uses a laser to fuse powder particles together, which allows the fabrication of personalized solid dosage forms. It possesses great potential for commercial use. However, a major drawback of SLS is the need to heat the powder bed while printing; this leads to high energy consumption (and hence a large carbon footprint), which may hinder its translation to industry. In this study, the concept of cold laser sintering (CLS) is introduced. In CLS, the aim is to sinter particles without heating the powder bed, where the energy from the laser, alone, is sufficient to fuse adjacent particles. The study demonstrated that a laser power above 1.8 W was sufficient to sinter both KollicoatIR and Eudragit L100-55-based formulations at room temperature. The cold sintering printing process was found to reduce carbon emissions by 99% compared to a commercial SLS printer. The CLS printed formulations possessed characteristics comparable to those made with conventional SLS printing, including a porous microstructure, fast disintegration time, and molecular dispersion of the drug. It was also possible to achieve higher drug loadings than was possible with conventional SLS printing. Increasing the laser power from 1.8 to 3.0 W increased the flexural strength of the printed formulations from 0.6 to 1.6 MPa, concomitantly increasing the disintegration time from 5 to over 300 s. CLS appears to offer a new route to laser-sintered pharmaceuticals that minimizes impact on the environment and is fit for purpose in Industry 5.0.
Objectives 3-Dimensional printing (3DP) is an additive manufacturing (AM) technique that is expanding quickly because of its low cost and excellent efficiency. The 3D printing industry grew by 19.5 % in 2021 in spite of the COVID-19 epidemic, and by 2026, the worldwide market is expected to be valued up to 37.2 billion US dollars. Content Science Direct, Scopus, MEDLINE, EMBASE, PubMed, DOAJ, and other academic databases provide evidence of the increased interest in 3DP technology and innovative drug delivery approaches in recent times. Summary In this review four main 3DP technologies that are appropriate for pharmaceutical applications: extrusion-based, powder-based, liquid-based, and sheet lamination-based systems are discussed. This study is focused on certain 3DP technologies that may be used to create dosage forms, pharmaceutical goods, and other items with broad regulatory acceptance and technological viability for use in commercial manufacturing. It also discusses pharmaceutical applications of 3DP in drug delivery and drug screening. Outlook The pharmaceutical sector has seen the prospect of 3D printing in risk assessment, medical personalisation, and the manufacture of complicated dose formulas at a reasonable cost. AM has great promise to revolutionise the manufacturing and use of medicines, especially in the field of personalized medicine. The need to understand more about the potential applications of 3DP in medical and pharmacological contexts has grown over time.
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