Micromolding as a potential manufacturing route for dry powder formulations

This is the second in a series of articles by Purdue scientists on new technologies in inhalation drug development.

As environmental concerns have lead pharmaceutical companies and regulators to work towards eliminating the use of propellants in inhalation devices, much of the recent research for pulmonary drug delivery has turned towards the use of dry powder inhalers (DPIs). Developing powder formulations for use in DPI devices presents significant challenges due to the small volume of API required, the need to generate a high fine particle fraction for delivery to the appropriate part of the airway, and the extremely narrow target range of particle size. Because particle size, density, and morphology determine the API’s handling and processing behaviors, including is interactions with excipients and its aerosolization properties, researchers have focused a great deal of attention on developing methods for better control of such characteristics. One new technique, microscale particle molding, also known as micromolding, represents a promising new method for achieving unprecedented control of such characteristics.