Melt Extrusion Research Articles

Modernizations of graphene nanocomposites using synthesis strategies—State-of-the-art

Graphene has been ranked among one of the most remarkable nanostructure of the carbon world. Graphene modification and nanocomposite formation have been used to expand the practical potential of graphene nanostructure. The overview is an effort to highpoint the indispensable synthesis strategies towards the formation of graphene nanocomposites. Consequently, graphene has been combined with useful matrices (thermoplastic, conducting, or others) to attain the desired end material. Common fabrication approaches like in-situ method, solution processing, and melt extrusion have been widely involved to form the graphene nanocomposites. Moreover, advanced sophisticated methods such as three or four dimensional printing, electrospinning, and others have been used to synthesize the graphene nanocomposites. Focus of all synthesis strategies has remained with the standardized graphene dispersion, physical properties, and applications. However, continuous future efforts are required to resolve the challenges in synthesis strategies and optimization of the parameters behind each technique. As the graphene nanocomposite design and properties directly depend upon the fabrication techniques used, there is obvious need for the development of advanced methods having better control over process parameters. Here, main challenging factors may involve the precise parameter control of the advanced techniques used for graphene nanocomposite manufacturing. Hence, there is not only need of current and future research to resolve the field challenges related to material fabrication but also reporting compiled review articles can be useful for interested field researchers towards challenge solving and future developments in graphene manufacturing.

Sustained release, antimicrobial, and antioxidant properties of modified porous starch-based biodegradable polylactic acid/polybutylene adipate-co-terephthalate/thermoplastic starch active packaging film

Porous starch (PS) is a modified starch with commendable biodegradable and adsorption properties. PS exhibits poor thermal stability, and the aqueous solution casting method is conventionally used for PS-activated packaging films. This approach limits the large-scale production of films and makes it difficult to play the functions of porous pores. In this study, PS was prepared by enzymatic digestion combined with freeze-drying and adsorbed with clove essential oil (CEO) after cross-linking with sodium trimetaphosphate. Subsequently, a novel PLA/PBAT/TPS/ScPS-CEO sustained release active packaging film was prepared by blending PLA, PBAT, TPS, and ScPS-CEO using industrial melt extrusion. Compared with PS, ScPS effectively slowed down the release of CEO from the film, with the maximum release of active substances at equilibrium increasing by approximately 100 %, which significantly enhanced the persistence of the antimicrobial and antioxidant properties. The polylactic acid/poly (butylene adipate-co-terephthalate)/thermoplastic starch/trimetaphosphate-crosslinked porous starch incorporated with clove essential oil (PLA/PBAT/TPS/ScPS-CEO) film could reduce the proteolysis, lipid oxidation and microbial growth of salmon, extending its shelf life by approximately 100 % at 4 °C. These results indicate that the ScPS can be used in fresh packaging material in practical applications.

Evaluation of the Viability of 3D Printing in Recycling Polymers.

The increased use of plastics in industrial and agricultural applications has led to high levels of pollution worldwide and is a significant challenge. To address this plastic pollution, conventional methods such as landfills and incineration are used, leading to further challenges such as the generation of greenhouse gas emissions. Therefore, increasing interest has been directed to identifying alternative methods to dispose of plastic waste from agriculture. The novelty of the current research arose from the lack of critical reviews on how 3-Dimensional (3D) printing was adopted for recycling plastics, its application in the production of agricultural plastics, and its specific benefits, disadvantages, and limitations in recycling plastics. The review paper offers novel insights regarding the application of 3D printing methods including Fused Particle Fabrication (FPF), Hot Melt Extrusion (HME), and Fused Deposition Modelling (FDM) to make filaments from plastics. However, the methods were adopted in local recycling setups where only small quantities of the raw materials were considered. Data was collected using a systematic review involving 39 studies. Findings showed that the application of the 3D printing methods led to the generation of agricultural plastics such as Polylactic Acid (PLA), Acrylonitrile Butadiene Styrene (ABS), Polyethylene Terephthalate (PET), and High-Density Polyethylene (HDPE), which were found to have properties comparable to those of virgin plastic, suggesting the viability of 3D printing in managing plastic pollution. However, limitations were also associated with the 3D printing methods; 3D-printed plastics deteriorated rapidly under Ultraviolet (UV) light and are non-biodegradable, posing further risks of plastic pollution. However, UV stabilization helps reduce plastic deterioration, thus increasing longevity and reducing disposal. Future directions emphasize identifying methods to reduce the deterioration of 3D-printed agricultural plastics and increasing their longevity in addition to UV stability.

Tribo-mechanical and structural characterizations of LLDPE matrix bio-composite reinforced with almond shell micro-particles: effects of the processing methodology

Abstract The objective of this research work is to examine the effect of mixing operation in the reinforcement of linear low density polyethylene (LLDPE) with almond shell powder (ASP). Two groups of bio-composites mixed in solid state and melt extrusion state were developed by the standard thermo compression molding process. For each group of bio-composites developed, the mass percentage of ASP was varied from 5 % to 40 %. Tensile and friction tests and micro structural analyzes were carried out. The main results show that the addition of ASP particles: decreases the maximum tensile stress and increases the rigidity of the two types of bio-composites produced. A significant improvement was observed in terms of maximum stress and Young’s modulus of the bio-composites mixed in the molten state compared to those mixed in the solid state. Microscopic observations concluded that the melt-blended ASPs were better covered by the LLDPE matrix and the dispersion was successfully achieved. Friction tests have shown an improvement in tribological performance thanks to the addition of an optimal percentage of ASP equal to 20 % in the case of bio-composites mixed in the molten state. From this research work, it can be concluded that the LLDPE/ASP homogenization method influences the mechanical and tribological properties of bio-composites.

Characteristics and Challenges of Poly(ethylene-co-vinyl acetate) Solution Electrospinning.

Poly(ethylene-co-vinyl acetate) (PEVA) is a versatile elastic, durable, and biocompatible copolymer, which can be processed by melt extrusion or solvent casting, while electrospinning has been reported as challenging. Here, a spinnability window should be identified using a total of 10 different PEVA materials with increasing vinyl acetate content (∼12-40 wt %) and molecular weights (∼60-130 kDa). Based on the solubility predictions by calculating Hansen solubility parameters, candidate solvents were experimentally evaluated. Spinning experiments with systematic alteration of solution composition and processing parameters revealed the causes of material deposition at the spraying nozzle and multijet spinning characteristics. By introducing a spinnability score that accounts for product characteristics and reproducibility, the spinnability of PEVA could be rationalized. Overall, it was demonstrated that PEVA solutions with an apparent viscosity of 920-3500 mPa·s can be spun to bead-free fibers of ∼10 μm. This size may allow suspension electrospinning of composite fibers in the future.

Polymeric field synergy principle: Revealing the intrinsic mechanism of screw channel optimization to enhance thermal management and process efficiency

The process efficiency and energy efficiency of extrusion equipment emerge as pivotal challenges constraining the development of the polymer extrusion industry. This article presents a new principle of polymeric field synergy to guide the solution to the low mixing efficiency and energy utilization efficiency of traditional extrusion equipment. Finite element analysis was conducted on four novel unconventional screw configurations and compared with the traditional single-thread screw. Results revealed that more complicated melt flow patterns generated in the modified novel screw configurations enhanced the stretching deformation or helical flow. The stretching or helical flows to varying degrees during the melt extrusion process thereby improved the mixing and heat transport efficiency. Among them, helical flow induced by the Maddock element exhibited the most significant impact on stretching flow and ductile deformation in the flow field. Simultaneously, the helical flow caused radial motion of the internal material, significantly promoting the synergy between the velocity field, velocity gradient field, and temperature gradient field. This enhanced radial heat and mass transport efficiency within the screw channel, subsequently improving the overall operational efficiency of the equipment. The results of the finite element analysis have substantiated the scientific validity of the polymeric field synergy principle.

HME-assisted formulation of taste-masked dispersible tablets of cefpodoxime proxetil and roxithromycin

ObjectivesAntibiotics are the most commonly administered medications among pediatric patients. However most of the time, accurate dose administration to children becomes a problem due to the extremely bitter taste. Cefpodoxime proxetil (CP) and roxithromycin (ROX) are antibiotics often prescribed to the pediatric population and have a bitter taste. Marketed formulations of these drugs are dry suspension and/or tablets. The lyophilization method involves various steps and thus is time consuming and expensive. The objective of this study was to mask the bitter taste of CP and ROX without compromising the solubility and drug release profile compared to marketed formulations, as well as to overcome the disadvantages associated with the currently used lyophilization technique. MethodsHot melt extrusion (HME) technology was used to process CP and ROX individually with Eudragit E PO polymer. The extrudates obtained were characterized by Fourier transform infrared spectroscopy, powder X-ray diffraction, and differential scanning calorimetry. The powdered extrudates were formulated as dispersible tablets and evaluated for in vitro and in vivo taste-masking efficiency. ResultsThe tablets prepared in this study showed comparable dissolution profiles but the taste-masking efficiency was significantly enhanced compared to the marketed tablets of CP and ROX. The results of in vivo human taste-masking evaluation were also in agreement with the in vitro taste-masking studies. ConclusionThe current work presents solvent-free, scalable, and continuous HME technology for addressing the bitter taste issues of CP and ROX. The disadvantages associated with the currently used lyophilization technique were overcome by developing the formulations using HME technology.

Formulation and Evaluation of Solid Dispersion of Felodipine by Hot Melt Extrusion for Enhancement of Solubility

ABSTRACT Background: Felodipine (BCS Class II) undergoes extensive first-pass metabolism with bioavailability of about 15% that creates problem in therapeutic efficacy after oral administration. Objective: Immediate release formulation of felodipine was developed using hot-melt extrusion (HME) technique in an attempt to improve solubility and dissolution of felodipine through the solid dispersion technique. Materials and Methods: The solid dispersion was prepared using Eudragit EPO, NE30D as a carrier with different drug polymer ratios using the HME technique. The optimized batch was made into tablets. The solid dispersion was characterized by solubility studies, drug content, and in vitro dissolution rate studies. Results: From the cumulative dissolution profile, it was observed that the drug and Eudragit EPO alone have the highest percentage of drug release compared to the other combinations of drug and Eudragit EPO, NE30D. It is also evident from the dissolution profile that with increase in the concentration of Eudragit NE30D, there is a decrease in the dissolution rate. There was a significant decrease in drug release even with increase in stabilizer in a smaller ratio. The dissolution profile showed that there is not much variation in the release profile of the solid dispersion alone and the solid dispersion tablets. Conclusions: Solid dispersion by the HME technique is an effective method to increase the dissolution rate of felodipine.

Enhancing 3D printability of polyhydroxybutyrate (PHB) and poly(3-hydroxybutyrate-co-3-hydroxy valerate) (PHBV) based blends through melt extrusion based-3D printing

Polyhydroxybutyrate (PHB) and poly (3-hydroxybutyrate-co-3-hydroxy valerate) (PHBV) possess favorable biological properties such as biocompatibility and biodegradability, making them suitable for various applications. However, their utility is limited by a narrow processing window due to low thermal stability and challenges in manipulating filament size during extrusion, attributed to poor melt strength. These issues result in irregularities such as discontinuous flow and incomplete deposition of melted PHB, significantly affecting 3D printing outcomes. To address these concerns, this study explores blending PHB and PHBV with poly (lactic acid) (PLA) and poly (butylene adipate-co-terephthalate) (PBAT) to enhance its processability and printability. Thermal analysis of all blends revealed three distinct degradation steps occurring at approximately 300, 360, and 400ºC, corresponding to PHB or PHBV, PLA, and PBAT, respectively. Moreover, the melting temperatures of PHB, PHBV, PLA, and PBAT were measured around 176, 173, 152, and 121ºC, respectively. It was observed that the polymer blends exhibited lower crystallization temperature and degree of crystallinity compared to PHB or PHBV. Assessing their 3D printability, neat PHB and PHBV filaments experienced fusion issues, poor flow during extrudate deposition, and significant warping, leading to 3D printing failures. In contrast, the blends displayed enhanced flowability and successfully produced high-quality specimens. Scanning electron microscope (SEM) analysis highlighted a phase separation morphology in the blends, showcasing uniform dispersion of PLA and PBAT within the PHB matrix.

Enhanced antifungal properties of poly(butylene succinate) film with lignin nanoparticles and trans-cinnamaldehyde for mango packaging

Sustainable poly(butylene succinate) (PBS) films incorporating lignin nanoparticles (LN) and trans-cinnamaldehyde (CN) have been developed to preserve mango freshness and provide food safety. PBS/LN, PBS/CN, and PBS/LN/CN composite films were produced by blown film melt extrusion. This study investigated the effect of CN-LN on the CN remaining content, thermal, mechanical, and barrier properties, diffusion coefficient, and antifungal activity of PBS films both in vitro and in vivo. Results showed that LN in the PBS/LN/CN composite film contained more CN than in the PBS/CN film. The compatibility of CN-LN with PBS produced homogeneous surfaces with enhanced barrier properties. PBS/LN/CN composite films demonstrated superior antifungal efficacy, inhibiting the growth of Colletotrichum gloeosporioides and preserving mango quality during storage. Results suggested that incorporating LN into PBS composite films prolonged the sustained release of antifungal agents, thereby inhibiting microbial growth and extending the shelf life of mangoes. Development of PBS/LN/CN composite films is a beneficial step toward reducing food waste and enhancing food safety.

Enhanced dielectric performance and thermal conductivity of the polyetherketoneketone composite films prepared via a facile template spray coating method

Polyetherketoneketone (PEKK) is a specialized engineering plastic renowned for its exceptional strength, high temperature resistance and chemical resistance. However, the high melting point of PEKK restricts its processing methods to traditional techniques such as melt extrusion, hot pressing, and molding, significantly limiting its application in the field of microelectronic devices. In this study, a facile template spray coating method was proposed to prepare highly flexible PEKK films. Furthermore, functionalized boron nitride-carbon nanotube (BN-CNT) hybrid fillers were prepared and incorporated into the PEKK matrix. The results demonstrated that when the content of BN-CNT hybrid filler was 5 wt%, the dielectric constant of the composite film ranges from 2.2 to 1.8 in the frequency range of 100–200000 Hz, with a dielectric loss value below 0.03. When the content of the hybrid filler increased to 20 wt%, the enhanced thermal conductive network results in a 640% increase in thermal conductivity compared to pure PEKK. The enhanced thermal conductivity of the composite films promoted heat dissipation of the computer CPU and accelerated the cooling rate. These findings demonstrate the great potential of the PEKK composite films for diverse applications in microelectronic devices.

Playing with Low Amounts of Expanded Graphite for Melt-Processed Polyamide and Copolyester Nanocomposites to Achieve Control of Mechanical, Tribological, Thermal and Dielectric Properties.

Polyamide 11 (PA11) and copolyester (TPC-E) were compounded through melt extrusion with low levels (below 10%) of expanded graphite (EG), aiming at the manufacturing of a thermally and electrically conductive composite resistant to friction and with acceptable mechanical properties. Thermal characterisation showed that the EG presence had no influence on the onset degradation temperature or melting temperature. While the specific density of the produced composite materials increased linearly with increasing levels of EG, the tensile modulus and flexural modulus showed a significant increase already at the introduction of 1 wt% EG. However, the elongation at break decreased significantly for higher loadings, which is typical for composite materials. We observed the increase in the dielectric and thermal conductivity, and the dissipated power displayed a much larger increase where high frequencies (e.g., 10 GHz) were taken into account. The tribological results showed significant changes at 4 wt% for the PA11 composite and 6 wt% for the TPC-E composite. Morphological analysis of the wear surfaces indicated that the main wear mechanism changed from abrasive wear to adhesive wear, which contributes to the enhanced wear resistance of the developed materials. Overall, we manufactured new composite materials with enhanced dielectric properties and superior wear resistance while maintaining good processability, specifically upon using 4-6 wt% of EG.

Understanding the Interaction of Thermal, Rheological, and Mechanical Parameters Critical for the Processability of Polyvinyl Alcohol-Based Systems during Hot Melt Extrusion.

Hot melt extrusion (HME) is a common manufacturing process used in the pharmaceutical industry to improve the solubility of poorly soluble active pharmaceutical ingredients (API). The goal is to create an amorphous solid dispersion (ASD) where the amorphous form of the API is stabilized within a polymer matrix. Traditionally, the development of pharmaceutically approved polymers has focused on requirements such as thermal properties, solubility, drug-polymer interactions, and biocompatibility. The mechanical properties of the material have often been neglected in the design of new polymers. However, new downstream methods require more flexible polymers or suitable plasticizer polymer combinations. In this study, two grades of the polymer polyvinyl alcohol (PVA), which is already established for HME, are investigated in terms of their mechanical, rheological, and thermal properties. The mechanical properties of the extruded filaments were tested by the three-point bending test. The rheological behavior was analyzed by oscillating plate measurements. Thermal analysis was performed by differential scanning calorimetry (DSC). In addition, the solid and liquid plasticizers mannitol, sorbitol, triacetin, triethyl citrate, polyethylene glycol, and glycerol were evaluated for use with PVA and their impact on the polymer properties was elaborated. Finally, the effects of the plasticizers are compared to each other, and the correlations are analyzed statistically using principal component analysis (PCA). Thereby, a clear ranking of the plasticizer effects was established, and a deeper understanding of the polymer-plasticizer interactions was created.

Facilely fabricated polyethylene film composed of directional microfibrils for passive radiative cooling

Nowadays, passive radiative cooling (PRC) has being attracted intensive attention because it can realize cooling effect without consuming any energy. Unfortunately, fabricating polymer film with radiative cooling effect by a facile, continuous and environmentally friendly method is still a large challenge. In this study, high density polyethylene (HDPE)/polyvinyl oxide (PEO) film were first fabricated by melt extrusion casting method, and polyethylene film composed of directional microfibrils (PFCDM) were finally obtained after selective dissolution of PEO phase in deionized water at 70 °C. The as-prepared PFCDM shows higher average solar reflectivity of 85.17% in the visible range and stronger average mid-infrared emissivity of 82.04% within the atmospheric window. It shows a sub-ambient cooling of 23.28 °C during the day and 3.1 °C at night, suggesting that it has a remarkable PRC performance. Moreover, the as-prepared PFCDM has outstanding wearability and self-cleaning property, showing promising potential of personal thermal management. This study proposes a facile but environmentally friendly method for fabricating PFCDM, paving a new way to develop wearable PRC film following the concept of thermoplastic polymers “functionalized” processing.

Formulation and evaluation of inhaled Sildenafil-loaded PLGA microparticles for treatment of pulmonary arterial hypertension (PAH): A novel high drug loaded formulation and scalable process via hot melt extrusion technology (Part Ⅰ)

In recent years, several techniques were employed to develop a local sustained pulmonary delivery of sildenafil citrate (SC) as an alternative for the intravenous and oral treatment of pulmonary arterial hypertension (PAH). Most of these methods, however, need to be improved due to limitations of scalability, low yield production, low drug loading, and stability issues. In this study, we report the use of hot-melt extrusion (HME) as a scalable process for making Poly (lactic-co-glycolic acid) (PLGA) microparticles with high SC load. The prepared particles were tested in vitro for local drug delivery to the lungs by inhalation. Sodium bicarbonate was included as a porogen in the formulation to make the particles more brittle and to impart favorable aerodynamic properties. Six formulations were prepared with different formulation compositions. Laser diffraction analysis was used to estimate the geometric particle size distribution of the microparticles. In-vitro aerodynamic performance was evaluated by the next-generation cascade impactor (NGI). It was reported in terms of an emitted dose (ED), an emitted fraction (EF%), a respirable fraction (RF%), a fine particle fraction (FPF%), a mass median aerodynamic diameter (MMAD), and geometric standard deviation (GSD). The formulations have also been characterized for surface morphology, entrapment efficiency, drug load, and in-vitro drug release. The results demonstrated that PLGA microparticles have a mean geometric particle size between 6 and 14 µm, entrapment efficiency of 77 to 89 %, and SC load between 17 and 33 % w/w. Fifteen percent of entrapped sildenafil was released over 24 h from the PLGA microparticles, and seventy percent over 7 days. The aerodynamic properties included fine particle fraction ranging between 19 and 33 % and an average mass median aerodynamic diameter of 6–13 µm.

Role of the plasticizers on the crystallization of PLA and its composites with mesoporous MCM-41

Several materials were prepared by melt extrusion, based on an L-rich polylactide (PLA), as polymeric matrix, acetyl tri-n-butyl citrate (ATBC) or trioctyl trimellitate (TOTM), as plasticizer, and mesoporous MCM-41 particles, playing a nucleant role. Influence of the addition of these nucleating particles, together with the comparative effect of the two plasticizers, has been thoroughly evaluated on the features of the several phase transitions existing in the PLA polymeric matrix (glass transition, cold crystallization, α′ to α transition, melting processes and melt crystallization) as well as on the rate of PLA crystallization. The window where this ordering process can take place is shifted down to lower temperatures for these binary and ternary systems and the range of temperatures at which the α′ and α polymorphs crystallize under isothermal crystallization from the glassy state significantly changes in the materials containing ATBC as plasticizer, either the binary or ternary ones. Type of the major crystalline lattice developed at 85 and 110 °C has been confirmed, additionally to the DSC experiments, by FTIR spectroscopy.Graphical abstract

Effects of Li addition on the properties of biodegradable Zn–Fe–Li alloy: Microstructure, mechanical properties, corrosion behavior, and cytocompatibility

Biodegradable Zn-based alloys have excellent mechanical properties, a good corrosion rate, and favorable biocompatibility, which have broad application prospects. In this study, new biodegradable Zn-0.5Fe-xLi (x = 0, 0.2, 0.5, 0.8 wt%) alloys were successively prepared by melting and hot extrusion, and the effects of Li content on the microstructure, mechanical properties, corrosion behavior, and biocompatibility of the alloys were investigated. The formation of FeZn13 and eutectic LiZn4 phases in the Zn-0.5Fe-xLi alloys and the grain size of the Zn-0.5Fe-0.5Li alloys significantly reduced with an increase in Li content. The synergistic effect of solid solution and grain refinement of Li significantly improved the strength of the Zn-0.5Fe-0.5Li alloy and ensured the ductility of the alloy, which resulted in its optimum overall performance. The yield strength was 353.6 ± 6.8 MPa, the ultimate tensile strength was 441.9 ± 2.6 MPa, and the elongation was 26.8 ± 0.8%. In addition, the Zn-0.5Fe-0.5Li alloy showed excellent corrosion properties. The electrochemical corrosion rate was 0.735 mm/year, and the surface corrosion degradation morphology was uniform after immersion. The Zn-0.5Fe-0.5Li alloy also demonstrated the most favorable in vitro cytocompatibility in cellular experiments. Overall, the extruded Zn-0.5Fe-0.5Li alloy is a promising biodegradable implant material with excellent mechanical properties, a suitable corrosion rate, and good cytocompatibility.

Insights into Factors Affecting Ethylene-Vinyl Acetate Copolymer Crystallinity in Islatravir Implant.

Islatravir, a highly potent nucleoside reverse transcriptase translocation inhibitor (NRTTI) for the treatment of HIV, has great potential to be formulated as ethylene-vinyl acetate (EVA) copolymer-based implants via hot melt extrusion. The crystallinity of EVA determines its physical and rheological properties and may impact the drug-eluting implant performance. Herein, we describe the systematic analysis of factors affecting the EVA crystallinity in islatravir implants. Differential scanning calorimetry (DSC) on EVA and solid-state NMR revealed drug loading promoted EVA crystallization, whereas BaSO4 loading had negligible impact on EVA crystallinity. The sterilization through γ-irradiation appeared to significantly impact the EVA crystallinity and surface characteristics of the implants. Furthermore, DSC analysis of thin implant slices prepared with an ultramicrotome indicated that the surface layer of the implant was more crystalline than the core. These findings provide critical insights into factors affecting the crystallinity, mechanical properties, and physicochemical properties of the EVA polymer matrix of extruded islatravir implants.

Characterization methods to predict extrusion performance in thermoplastic polyurethane batches

Thermoplastic polyurethanes (TPUs) are a class of urethane elastomers which flow at elevated temperatures, enabling a diverse set of processing techniques including industrial-scale extrusion and injection molding. Due to variations in the relative content of hard and soft segments within the polymer chains, as well as block lengths and chemistries, this material exhibits a wide range of viscoelastic properties depending on the synthetic process and thermal history. Numerous manufacturers produce their own proprietary brands of TPU, thus creating a diverse market for a product whose processability varies depending on the supplier. Lot dependent undesirable characteristics may be observed during melt extrusion, including degradation at process-relevant temperatures, increases in viscosity over time, and buildup of solid-like particulates during extrusion. This manuscript implements a combination of chemorheological, spectroscopic, solubility, light scattering, and calorimetric techniques to understand the formation of this solid particulate phase during extrusion. The presence of endothermic transitions, large degrees of branching, rapidly changing viscoelastic properties, and poor dissolution capabilities were correlated with the worst performing lots of TPU in terms of extrudability. These findings suggest that solidification is caused by physical crosslinking through hard phase aggregation, which is attributed to differences in polymer branching architecture, high chain mobility, and strain under extrusion conditions. The strong association between polymer branching and solidification during extrusion highlights the capability for these characterization techniques to rapidly screen for extrusion-related performance of TPUs prior to processing.

Colon-targeted 3D-Printed mesalamine tablets: Core-shell design and in vitro/ex-vivo evaluation

ObjectivesThe present study is intended to develop a shell-core tablet using a hot melt extrusion (HME)-based dual-nozzle fused deposition modeling (FDM) three-dimensional (3D) printing approach. The primary objective was to establish a sustained-release colonic drug delivery system and improve mesalamine's permeability by incorporating Vitamin E TPGS as a permeation enhancer. MethodThe study utilized Kollidon® SR for sustained release, L-100, and HPMC HME L100 for the tablet's protective shell. Six filament formulations were tested, and the mechanical properties of the shell filaments, including the three-point bending, Hooke's law, and stiffness, were assessed. Drug release profiles of the tablets were evaluated using the USP-II dissolution apparatus, and permeability characteristics were gauged using the non-everted intestinal sac method. Solutions containing 5% w/v mesalamine and 2.5% w/v Vitamin E TPGS were employed, with pure mesalamine as a control. ResultsOptimal filament ratios were identified as 50:50 for the core and 30:70 for Eudragit L-100 to HPMC HME L100 for the shell. The resulting tablets achieved a prolonged drug release of up to 24 h for the core. They ensured minimal drug release in the upper gastrointestinal tract (∼5% in the first 5 h), effectively targeting the colon. Incorporating Vitamin E TPGS led to a 3.6-fold increase in mesalamine absorption compared to the control, and the addition of Kollidon® SR notably improved the flow properties of Mesalamine powder. ConclusionIn conclusion, this innovative approach has the potential to achieve a colon-specific drug delivery system.