Electrodeless Electrohydrodynamic Drop-on-Demand Encapsulation of Drugs into Porous Polymer Films for Fabrication of Personalized Dosage Units

Noncontact drop-on-demand (DOD) dosing is a promising strategy for manufacturing of personalized dosage units. However, current DOD methods developed for printing chemically and thermally stable, low-viscosity inks are of limited use for pharmaceuticals due to fundamentally different functional requirements. To overcome their deficiency, we developed a novel electrohydrodynamic (EHD) DOD (Appl, Phys, Lett. 97, 233501, 2010) that operates on fluids of up to 30 Pa·s in viscosity over a wide range of droplet sizes and provides a precise control over the droplet volume. We now evaluate the EHD DOD as a method for fabrication of dosage units by printing drug solutions on porous polymer films prepared by freeze-drying. Experiments were carried out on ibuprofen and griseofulvin, as model poorly water-soluble drugs, polyethylene glycol 400, as a drug carrier, and hydroxypropyl methylcellulose films. The similarities between drug release profiles from different dosage units were assessed by model-independent difference, f1, and similarity, f2, factors. The results presented show that EHD DOD offers a powerful tool for the evolving field of small-scale pharmaceutical technologies for tailoring medicines to individual patient's needs by printing a vast array of predefined amounts of therapeutics arranged in a specific pattern on a porous film. © 2012 Wiley Periodicals, Inc. and the American Pharmacists Association