New active dry powder inhaler systems were developed and tested to
efficiently aerosolize a carrier-free formulation. To assess inhaler
performance, a challenging case study of aerosol lung delivery during high-flow
nasal cannula (HFNC) therapy was selected. The active delivery system consisted
of a ventilation bag for actuating the device, the DPI containing a flow control
orifice and 3D rod array, and streamlined nasal cannula with separate inlets for
the aerosol and HFNC therapy gas. In vitro experiments were
conducted to assess deposition in the device, emitted dose (ED) from the nasal
cannula, and powder deaggregation. The best performing systems achieved EDs of
70–80% with fine particle fractions <5 μm of
65–85% and mass median aerodynamic diameters of 1.5 μm,
which were target conditions for controlled condensational growth aerosol
delivery. Decreasing the size of the flow control orifice from 3.6 to 2.3 mm
reduced the flow rate through the system with manual bag actuations from an
average of 35 to 15 LPM, while improving ED and aerosolization performance. The
new devices can be applied to improve aerosol delivery during mechanical
ventilation, nose-to-lung aerosol administration, and to assist patients that
cannot reproducibly use passive DPIs.