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In the present work, we explored Lewis acid catalysis, via FeCl3, for the heterogeneous surface functionalization of cellulose nanofibrils (CNFs). This approach, characterized by its simplicity and efficiency, facilitates the amidation of nonactivated carboxylic acids in carboxymethylated cellulose nanofibrils (c-CNF). Following the optimization of reaction conditions, we successfully introduced amine-containing polymers, such as polyethylenimine and Jeffamine, onto nanofibers. This introduction significantly enhanced the physicochemical properties of the CNF-based materials, resulting in improved characteristics such as adhesiveness and thermal stability. Reaction mechanistic investigations suggested that endocyclic oxygen of cellulose finely stabilizes the transition state required for further functionalization. Notably, a nanocomposite, containing CNF and a branched low molecular weight polyethylenimine (CNF-PEI 800), was synthesized using the catalytic reaction. The composite CNF-PEI 800 was thoroughly characterized having in mind its potential application as coating biomaterial for medical implants. The resulting CNF-PEI 800 hydrogel exhibits adhesive properties, which complement the established antibacterial qualities of polyethylenimine. Furthermore, CNF-PEI 800 demonstrates its ability to support the proliferation and differentiation of primary human osteoblasts over a period of 7 days.

Poorly soluble drugs represent a substantial portion of emerging drug candidates, posing significant challenges for pharmaceutical formulators. One promising method to enhance the drug’s dissolution rate and, consequently, bioavailability involves transforming them into an amorphous state within mesoporous materials. These materials can then be seamlessly integrated into personalized drug formulations using Additive Manufacturing (AM) techniques, most commonly via Fused Deposition Modeling. Another innovative approach within the realm of AM for mesoporous material-based formulations is semi-solid extrusion (SSE). This study showcases the feasibility of a straightforward yet groundbreaking hybrid 3D printing system employing SSE to incorporate drug-loaded mesoporous magnesium carbonate (MMC) into two different drug formulations, each designed for distinct administration routes. MMC was loaded with the poorly water-soluble drug ibuprofen via a solvent evaporation method and mixed with PEG 400 as a binder and lubricant, facilitating subsequent SSE. The formulation is non-aqueous, unlike most pastes which are used for SSE, and thus is beneficial for the incorporation of poorly water-soluble drugs. The 3D printing process yielded tablets for oral administration and suppositories for rectal administration, which were then analyzed for their dissolution behavior in biorelevant media. These investigations revealed enhancements in the dissolution kinetics of the amorphous drug-loaded MMC formulations. Furthermore, an impressive drug loading of 15.3 % w/w of the total formulation was achieved, marking the highest reported loading for SSE formulations incorporating mesoporous materials to stabilize drugs in their amorphous state by a wide margin. This simple formulation containing PEG 400 also showed advantages over other aqueous formulations for SSE in that the formulations did not exhibit weight loss or changes in size or form during the curing process post-printing. These results underscore the substantial potential of this innovative hybrid 3D printing system for the development of drug dosage forms, particularly for improving the release profile of poorly water-soluble drugs.

Fused deposition modeling (FDM) and selective laser sintering (SLS) are two of the most employed additive manufacturing (AM) techniques within the pharmaceutical research field. Despite the numerous advantages of different AM methods, their respective drawbacks have yet to be fully addressed, and therefore combinatorial systems are starting to emerge. In the present study, hybrid systems comprising SLS inserts and a two-compartment FDM shell are developed to achieve controlled release of the model drug theophylline. Via the use of SLS a partial amorphization of the drug is demonstrated, which can be advantageous in the case of poorly soluble drugs, and it is shown that sintering parameters can regulate the dosage and release kinetics of the drug from the inserts. Furthermore, via different combinations of inserts within the FDM-printed shell, various drug release patterns, such as a two-step or prolonged release, can be achieved. The study serves as a proof of concept, highlighting the advantages of combining two AM techniques, both to overcome their respective shortcomings and to develop modular and highly tunable drug delivery devices.

The aim of this study is to investigate the influence of polymer chemistry on the properties of oral dosage forms produced using selective laser sintering (SLS). The dosage forms were printed using different grades of polyvinyl alcohol or copovidone in combination with indomethacin as the active pharmaceutical ingredient. The properties of the printed structures were assessed according to European Pharmacopoeia guidelines at different printing temperatures and laser scanning speeds in order to determine the suitable printing parameters.

The results of the study indicate that the chemical properties of the polymers, such as dynamic viscosity, degree of hydrolyzation, and molecular weight, have significant impact on drug release and kinetics. Drug release rate and supersaturation can be modulated by selecting the appropriate polymer type. Furthermore, the physical properties of the dosage forms printed under the same settings are influenced by the selected polymer type, which determines the ideal manufacturing settings.

This study demonstrates how the chemical properties of the polymer can determine the appropriate choice of manufacturing settings and the final properties of oral dosage forms produced using SLS.

Additive Manufacturing (AM) is a fast-growing approach to produce personalized oral dosage forms. Even though some AM technologies are promising as alternative to conventional compounding with resulting dosage manipulation, they still suffer from a lack of quality control. Due to the high regulatory demands and standards applied to dosage forms in the case of dose accuracy and tablet properties such as friability, effective quality control is a key feature in promoting AM as a valid technology for patient-tailored medications. One of the AM techniques used is selective laser sintering, which allows for capturing the surface state layer-by-layer during the printing process. It provides the opportunity to apply non-destructive quality control based on image analysis extracting essential data at each layer of the sintering process. This work is devoted to establishing the value of data gathered via thermal image analysis for the subsequent quality control.

Large batches of placebo and drug-loaded solid dosage forms were successfully fabricated using selective laser sintering (SLS) 3D printing in this study. The tablet batches were prepared using either copovidone (N-vinyl-2-pyrrolidone and vinyl acetate, PVP/VA) or polyvinyl alcohol (PVA) and activated carbon (AC) as radiation absorbent, which was added to improve the sintering of the polymer. The physical properties of the dosage forms were evaluated at different pigment concentrations (i.e., 0.5 and 1.0 wt%) and at different laser energy inputs. The mass, hardness, and friability of the tablets were found to be tunable and structures with greater mass and mechanical strength were obtained with increasing carbon concentration and energy input. Amorphization of the active pharmaceutical ingredient in the drug-loaded batches, containing 10 wt% naproxen and 1 wt% AC, was achieved in-situ during printing. Thus, amorphous solid dispersions were prepared in a single-step process and produced tablets with mass losses below 1 wt%. These findings show how the properties of dosage forms can be tuned by careful selection of the process parameters and the powder formulation. SLS 3D printing can therefore be considered to be an interesting and promising technique for the fabrication of personalized medicines.

Suboptimal treatment caused by inaccurate dosing of prescribed medications is a challenging issue for the pharmaceutical industry. As a result, certain groups of patients, especially pediatric patients, may suffer from a lack of specific dosage forms, leading to potential side effects. To address this issue, various manipulation techniques are being applied, such as tablet crushing, splitting, and solution preparations. Unfortunately, these methods lack accuracy and economic efficiency.

3D printing technology has been considered one of the potential solutions for manufacturing limited batch dosage forms. Dosage forms produced through 3D printing can be fabricated on demand for specific patients. Furthermore, the unique properties of these dosage forms, such as API amorphization, can be adjusted due to the high tunability of the 3D printing process. The work conducted in this thesis is dedicated to investigating the potential applications of Selective Laser Sintering (SLS) and the associated aspects of this method for manufacturing solid dosage forms.

The investigations into printing parameters and formulation content enabled the establishment of correlations between these factors and the properties of the final dosage forms. Higher print temperature, Laser Power Ratio, and colorant concentration led to increased mass and hardness of the dosage forms.

The polymer constitutes the major portion of the formulation in terms of mass. Consequently, various grades of polymer were examined to ascertain their chemical influence on the properties of the dosage forms. The findings revealed that the type of polymer, degree of hydrolysis, and dynamic viscosity of the polymer significantly impact both the dissolution rate and API amorphization.

Utilizing FDM for printing the shell component of the drug delivery device improved its durability, whereas the SLS-printed insert resulted in a faster and adjustable dissolution rate. This experiment showcased the potential of combining the advantages of each technique to produce dosage forms with additional features.

A thermal image analysis device was developed and employed to monitor temperature conditions throughout the printing process. The outcomes demonstrated that the collected data could be utilized for in-process quality control objectives and serve as a dataset for machine learning algorithms. This capability allows for real-time process monitoring, defect detection, and automated process refinement.

In conclusion, a comprehensive study was conducted on the application of SLS and its limitations. This study will hopefully pave the way for further discussions and the implementation of this technology.

The CO₂ sorption properties of sodium hafnium oxide (Na₂HfO₃) were investigated in this study. Na₂HfO₃ was synthesized by solid-state synthesis using Na₂CO₃ and HfO₂ as starting materials. The solid-state synthesized Na₂HfO₃ appeared structurally similar to other mixed metal oxides such as Na₂ZrO_3, but stacking disorder appeared to be common in Na₂HfO₃. The synthesis conditions, including the Na : Hf ratio (between 0.5 and 1.5 : 1), synthesis temperature, time and heating rate, were investigated to optimize CO₂ sorption properties of Na₂HfO₃. The Na₂HfO₃ sorbent showed comparable CO₂ uptake capacity, reaction rate and excellent cycling stability compared to other metal oxide sorbents. Na₂HfO₃ with Na : Hf = 1 : 1 and 1.25 : 1 showed the highest CO₂ uptake among all Na₂HfO₃ samples obtained, with a CO₂ uptake capacity of around 15 wt% (at 650–800 °C). The CO₂ uptake rate of NHO-1 and NHO-1.25 was fast with over 80% of the equilibrium uptake reached within 250 s. Na₂HfO₃ remained stable even after 100 cycles with less than 3% difference in the CO₂ uptake capacity between the 1st and 100th cycles. We performed kinetic analysis on the CO₂ sorption data and found that the Avrami–Erofeev model fitted the kinetic data best among the kinetic models used. Apart from sorbent optimization, we showed that 3D-printing of Na₂HfO₃ : HfO₂ mixtures can be used to produce structured Na₂HfO₃ sorbents with a slightly improved CO₂ uptake rate and the same CO₂ uptake capacity as the powder-based solid-state synthesized Na₂HfO₃ sorbent.