- Author(s):
- Organization(s):
Kiel University
Carrier-based interactive powder mixtures are a cornerstone of drug delivery by inhalation, yet optimization is hampered by the complex interplay of various carrier particle properties including their geometry. Conventional approaches for carrier particle manufacture such as milling, sieving or spray drying can modify multiple attributes simultaneously, making it challenging to assess the effect of particle geometry. To address this, two innovative strategies were applied and are presented in this article: in-silico modeling and the use of 3D-printed carrier particles.
Four particle geometries—Sphere, Soccerball, Rollingknot and Pharmacone—were investigated, with the Pharmacone exhibiting superior performance. Next, a parametric Satellite geometry was created and optimized through a fully automated in-silico workflow integrating Bayesian optimization, identifying design rules for spike dimensions and surface features. These studies demonstrate that carrier geometry is a critical determinant of drug detachment and aerosolization efficiency. Together, advanced 3D printing and in-silico optimization can provide a powerful framework for designing carrier particles with tailored geometries, offering new opportunities to enhance the performance of dry powder inhalers.
August 2026, Volume 20(4), pages 10-16