A team of researchers, led by Professor Regina Scherließ from Kiel University (CAU), is well on their way to accomplishing that goal. Now, they’re creating smart carrier microparticles for inhaled medicines. Instead, the team has leveraged a new 3D printing approach known as multi-focus multi-photon 3D laser printing. They succeeded in forming millions of perfectly shaped particles to make drug delivery more effective. The innovative heroine’s approach was recently documented in the journal Communications Materials.
Her innovative, multi-focus multi-photon 3D laser printing process makes these carrier particles in jaw-dropping detail. This revolutionary process takes the art of precision manufacturing to a new level. Operating with nanometer resolution through a process called two-photon polymerization, the technology enables the production of over 2 million identical particles for each of the four distinct designs tested. These designs included cutting edge geometric forms such as Pharmacone, Soccerball, Sphere and Rollingknot. Each nozzle shape was subject to a detailed review to assess the shape’s efficacy in the inhalation process.
High-Precision Particle Production
This encapsulation of model carriers microparticles is a significant advance in pharmaceutical technology. The unique approach of the team enables highly accurate definition of complex geometries down to micron-sized carrier particles.
Professor Scherließ noted the impact of this technology on pharmaceutical development:
“Our results show that modern technologies such as high-resolution 3D printing are opening entirely new avenues in pharmaceutical development.”
The researchers tested the effects of a variety of surface roughness, from fine to coarse, on a specialized aerodynamic shape. Their goal was to identify how these discrepancies impact drug delivery during inhalation.
Melvin Wostry, a member of the research team, emphasized the importance of particle detachment in effective drug delivery:
“For the drug to be effective, it has to detach from the carrier when inhaled and reach the lungs with the airflow. If it sticks, it is simply swallowed and never reaches its target.”
This study highlights the importance of particle geometry in optimizing inhalation therapy.
Performance of Microparticle Designs
The findings from round one testing indicated that one design, ‘Pharmacone’, stood head and shoulder above the rest. Its star-like geometry has a number of spikes extending from the surface. This design significantly increases the invention’s effectiveness as a carrier for inhaled medicines.
She continued to describe how the fine particle fraction—the drug particles that can be inhaled, less than 5 micrometers—was four times greater with this geometry. This level of performance is orders of magnitude better than the next-best design. Pharmacon accelerates drug delivery to the lungs. It further increases the likelihood that federal investments will actually achieve their intended targets in the most effective manner possible.
“One shape we call ‘Pharmacone’ was the clear winner. Its star-like geometry features several protruding tips on the surface.”
The effects of this research are huge for the future of inhaled medications. The potential to intentionally affect medication interaction through design creates an opportunity that should prove to be both advantageous and rewarding for pharmaceutical scientists. The team’s discoveries may now open the door to personalized therapies that better address the needs of individual patients.
Implications for Future Research
This creative new 3D printing approach is cutting-edge and ever-developing. It holds the potential to accelerate the development and delivery of inhaled medicines and bring great health outcomes to patients suffering from respiratory disease.
Professor Scherließ stated:
“We can now deliberately influence the behavior of medications through design—a kind of fine-tuning on the micrometer scale.”
As this innovative 3D printing method continues to evolve, it promises to transform how inhaled medicines are developed and delivered, ultimately improving outcomes for patients with respiratory conditions.