A reliable in vitro system can support and guide the
development
of subcutaneous (SC) drug products. Although several in vitro systems
have been developed, they have some limitations, which may hinder
them from getting more engaged in SC drug product development. This
study sought to develop a novel in vitro system, namely, Emulator of SubCutaneous Absorption and Release (ESCAR), to better emulate the in vivo SC environment and
predict the fate of drugs in SC delivery. ESCAR was designed using
computer-aided design (CAD) software and fabricated using the three-dimensional
(3D) printing technique. ESCAR has a design of two acceptor chambers
representing the blood uptake pathway and the lymphatic uptake pathway,
respectively, although only the blood uptake pathway was investigated
for small molecules in this study. Via conducting a DoE factor screening
study using acetaminophen solution, the relationship of the output
(drug release from the “SC” chamber to the “blood
circulation” chamber) and the input parameters could be modeled
using a variety of methods, including polynomial equations, machine
learning methods, and Monte Carlo simulation-based methods. The results
suggested that the hyaluronic acid (HA) concentration was a critical
parameter, whereas the influence of the injection volume and injection
position was not substantial. An in vitro–in vivo correlation
(IVIVC) study was developed using griseofulvin suspension to explore
the feasibility of applying ESCAR in formulation development and bioequivalence
studies. The developed LEVEL A IVIVC model demonstrated that the in
vivo PK profile could be correlated with the in vitro release profile.
Therefore, using this model, for new formulations, only in vitro studies
need to be conducted in ESCAR, and in vivo studies might be waived.
In conclusion, ESCAR had important implications for research and development
and quality control of SC drug products. Future work would be focused
on further optimizing ESCAR and expanding its applications via assessing
more types of molecules and formulations.