PRINTING DRUG TABLETS WITH FULLY CUSTOMIZABLE RELEASE PROFILES FOR PERSONALIZED MEDICINE
20180214383 ยท 2018-08-02
Inventors
Cpc classification
A61K9/2072
HUMAN NECESSITIES
A61K9/2031
HUMAN NECESSITIES
International classification
Abstract
Provided herein is a method for producing a dosage form that can be customized according to a patient's needs. In particular, the invention relates to dosage forms comprising an erodible polymer and an active pharmaceutical agent, wherein the erodible polymer is designed to have a specified geometric shape. As described herein, the active agent is released from the dosage form as a function of the geometric shape of the erodible polymer.
Claims
1. A dosage form, comprising: a first erodible polymer having a first three-dimensional geometric shape and comprising at least one active pharmaceutical agent; a second erodible polymer that surrounds the first erodible polymer to form an erodible composite, said composite having a second three-dimensional geometric shape having a first end and a second end along a y-axis; and a non-erodible housing that encapsulates the erodible composite except at the first end along the y-axis.
2. The dosage form of claim 1, further comprising a third polymer having a third three-dimensional geometric shape and comprising one or more additional active pharmaceutical agent.
3. The dosage form of claim 1, wherein the non-erodible housing is biodegradable.
4. The dosage form of claim 3, wherein the biodegradable housing comprises a polymer.
5. The dosage form of claim 4, wherein the polymer is polylactic acid (PLA).
6. The dosage form of claim 1, wherein the first geometric shape is symmetric along a y-axis, or symmetric along an x-axis, or both.
7. The dosage form of claim 1, wherein the first geometric shape is asymmetric along a y-axis, or asymmetric along an x-axis, or both.
8. The dosage form of claim 6, wherein the geometric shape is a square box; a rectangular box; a cylinder of any aspect ratio with flat ends; a cylinder of any aspect ratio with rounded ends; spherical; ellipsoidal; or a three-dimensional diamond.
9. The dosage form of claim 7, wherein the geometric shape is a three-dimensional triangle.
10. A method of delivering a variable dosage form comprising administering the variable dosage form to a subject, wherein the dosage form comprises: a first erodible polymer having a first three-dimensional geometric shape and comprising at least one active pharmaceutical agent; a second erodible polymer that surrounds the first erodible polymer to form an erodible composite, said composite having a second three-dimensional geometric shape having a first end and a second end along a y-axis, and a non-erodible housing that encapsulates the erodible composite except at the first end along the y-axis; wherein, upon contact with a surrounding solvent, the active pharmaceutical agent is released from the first end of the erodible composite as a function of the first geometric shape of the first erodible polymer, to deliver a variable dosage to the subject.
11. The method of claim 10, wherein the dosage form further comprises a third polymer having a third three-dimensional geometric shape and comprising one or more additional active pharmaceutical agent.
12. The method of claim 10, wherein the non-erodible housing is biodegradable.
13. The method of claim 12, wherein the biodegradable housing comprises a polymer.
14. The method of claim 10, wherein the first geometric shape is symmetric along a y-axis, or symmetric along an x-axis, or both.
15. The method of claim 10, wherein the first geometric shape is asymmetric along a y-axis, or asymmetric along an x-axis, or both.
16. The method of claim 14, wherein the geometric shape is a square box; a rectangular box; a cylinder of any aspect ratio with flat ends; a cylinder of any aspect ratio with rounded ends; spherical; ellipsoidal; or a three-dimensional diamond.
17. The method of claim 15, wherein the geometric shape is a three-dimensional triangle.
18. A method of producing a variable dosage form, comprising: a) providing a mold having a first three-dimensional geometric shape; b) filling the mold with a first solution comprising a first polymer and at least one active pharmaceutical agent; c) polymerizing the first solution comprising the first polymer and the at least one active pharmaceutical agent to form a first solid erodible polymer; d) placing the first solid erodible polymer into a three-dimensionally printed non-erodible housing having an opening on one end; e) filling the housing with a second solution comprising a second polymer; and f) polymerizing the second solution comprising the second polymer, forming an erodible composite that includes the first solid erodible polymer to form a variable dosage form.
19. The method of claim 18, wherein the first geometric shape of the variable dosage form is determined according to a diagnosis made for a patient in need of treatment with a variable dosage form.
20. The method of claim 18, wherein the mold is formed from a three-dimensionally printed template having the first three-dimensional geometric shape.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] The foregoing will be apparent from the following more particular description of example embodiments of the invention, as illustrated in the accompanying drawings in which like reference characters refer to the same parts throughout the different views. The drawings are not necessarily to scale, emphasis instead being placed upon illustrating embodiments of the present invention.
[0007]
[0008]
[0009]
[0010]
[0011]
[0012]
DETAILED DESCRIPTION OF THE INVENTION
[0013] A description of example embodiments of the invention follows.
[0014] The present invention provides compositions and methods for customizing the release profile of an active pharmaceutical agent. Generally, a commercially-available three-dimensional (3D) printer is used to print a template having a desired three-dimensional geometric shape, which determines the type of release profile. Because the 3D printer has the flexibility to print any desired three-dimensional shape, the present methods can be used to make fully customizable release profiles.
[0015]
[0016]
[0017] The invention also provides a method to tune the composition of the erodible polymer to either stretch (extend) or compress (shorten) the period of time that the drug is released (with its desired, unique release profile), as exemplified herein (
[0018] The present invention is applicable for either mass production of drug tablets, or at a smaller scale that is personalized for the individual patient. For example, in the latter scenario, the present invention can be practiced in a clinical setting where a healthcare provider can decide the desired release profile for the particular patient. The tablet (with this desired profile) can then be fabricated in the same place, and be dispensed to the patient immediately. Thus, in certain aspects, the present invention can be used in the area of personalized medicine, enabling the design of a dosage form to suit the needs of an individual patient.
[0019] Accordingly, in one aspect, the present invention provides a dosage form, comprising a first erodible polymer having a first three-dimensional geometric shape and comprising at least one active pharmaceutical agent. The dosage form also comprises a second erodible polymer that surrounds the first erodible polymer to form an erodible composite, said composite having a second three-dimensional geometric shape having a first end and a second end along a y-axis. In a particular embodiment, the second erodible polymer does not contain an active pharmaceutical agent. A non-erodible housing encapsulates the erodible composite except at the first end along the y-axis.
[0020] The erodible composite of the resulting dosage form is exposed to the environment (e.g., physiological environment) at the first end (that is, at one end of the dosage formsee, e.g.,
[0021] Generally, the first erodible solid polymer having a first three-dimensional geometric shape is positioned in the center of the composite (see, e.g.,
[0022] As described herein, the housing of the dosage form is also 3D printed using, e.g., a commercially available 3D printer. The housing serves as a barrier to protect all but one side of the dosage form from eroding such that the drug is release only from a specific opening (the release is one-dimensional). See, e.g.,
[0023] The first erodible solid polymer having a first geometric shape sits inside the housing, positioned according to an x- and y-axis as depicted in
[0024] In some embodiments, the dosage form can be designed to release more than one active pharmaceutical agent. For example, the first erodible solid polymer having a first three-dimensional geometric shape can be formed from alternating layers of 2 or more drugs such that different drugs can be released sequentially. In a simple scenario, the first erodible polymer can be a three-dimensional rectangle capable of releasing two drugs, each drug layered in an alternating fashion such that erosion of the polymer along the y-axis will release each drug sequentially. In other embodiments, the dosage form further comprises a third solid erodible polymer having a third three-dimensional geometric shape and comprises one or more additional active pharmaceutical agent. The third erodible polymer can be the same polymer as that of the first erodible polymer, or a different polymer that erodes at a similar rate as the first polymer. In various embodiments, the third erodible polymer can be the same shape as the first erodible polymer to produce the same, simultaneous release profile. In one embodiment, the third erodible polymer can be the same shape as the first erodible polymer, but positioned in the housing so as to produce the reverse release profile (see
[0025] In other aspects, the present invention also provides a method of delivering a variable dosage form, comprising administering the variable dosage form as described herein to a subject in need of a treatment, wherein, upon contact with a surrounding solvent, the active pharmaceutical agent is released from the first end of the solid erodible composite as a function of the first geometric shape of the first erodible polymer to deliver a variable dosage to the subject.
[0026] In further aspects, the present invention provides a method of producing a variable dosage form as described herein, comprising providing a mold having a first 3D geometric shape, such as by three-dimensionally printing a template have a three-dimensional geometric shape; filling the mold with a first solution comprising a first polymer and at least one active pharmaceutical agent; polymerizing the first solution comprising the first polymer and the at least one active pharmaceutical agent to form a first solid erodible polymer; placing the first solid erodible polymer into a three-dimensionally printed non-erodible housing having an opening on one end; filling the housing with a second solution comprising a second polymer; and polymerizing the second solution comprising the second polymer to form an erodible composite that includes the first solid erodible polymer to form a variable dosage form. In certain embodiments, the method further comprises three-dimensionally printing a template (e.g., an embossed template) having a desired three-dimensional geometric shape. As described herein, a mold is formed using the three-dimensionally printed embossed template having a desired 3D geometric shape. For example, the embossed template is placed in a container with the embossed side up, and a solution containing, e.g., polydimethylsiloxane (PDMS) is poured into the container. Upon curing the solution, a mold having a cavity with the 3D geometric shape of the embossed template is formed. This mold can be used to fill with a solution comprising a polymer and at least one active pharmaceutical agent. See, e.g.,
[0027] In another related aspect, the present invention also provides a method of producing a variable dosage form as described herein, comprising providing a mold having a first three-dimensional geometric shape (e.g., three-dimensionally printing a mold having a first three-dimensional geometric shape); filling the mold having a first 3D geometric shape with a first solution comprising a first erodible polymer and at least one active pharmaceutical agent; polymerizing the first solution comprising the first erodible polymer and the at least one active pharmaceutical agent to form a first solid erodible polymer; placing the first solid erodible polymer into a three-dimensionally printed non-erodible housing having an opening on one end; filling the housing with a second solution comprising a second erodible polymer; and polymerizing the second solution comprising the second erodible polymer forming an erodible composite that includes the first solid erodible polymer to form a variable dosage form. In one embodiment, the mold is 3D-printed. In additional embodiments, the mold comprises a cavity having a three-dimensional geometric shape. As described herein, the 3D-printed mold comprising a cavity having a three-dimensional geometric shape can be used to fill with a solution comprising a polymer and at least one active pharmaceutical agent. See, e.g.,
[0028] As will be appreciated by those of skill in the art, the geometric shape of the erodible polymer comprising an active pharmaceutical agent is determined according to the condition of a patient in need of treatment (i.e., according to a diagnosis made for a patient in need of treatment with a variable dosage form). For example, constant and continuous release can be achieved by, for example, a rectangular shape depicted in the first shape from the left of
EXAMPLES
[0029] Release Rate as a Function of the Geometric Shape of the Erodible Polymer
[0030] Materials and Methods
[0031] Five three-dimensional geometric shapes were selected for demonstration of release profiles (
[0032] The dye-containing polymer was generated as follows: 4-pentenoic anhydride (PNA), pentaerythritol tetrakis(3-mercaptopropionate) (PETMP) and 2,2-(Ethylenedioxy) diethanethiol (EGDT) were mixed together, and 0.1 wt % 1-hydroxycyclohexyl phenyl ketone was then added as the photoinitiator. The mole ratio for PNA and the total amount of both cross-linkers used was 1:1. Two different mole ratios were used in this studyPNA:PETMP: EGDT=1:0.75:0.25, and 1:0.9:0.1. The solution was then purged with nitrogen for three minutes. 6 to 8 mg of a dye (Orange G or Brilliant Blue G) were then added to 0.2 mL of the purged solution, and mixed thoroughly using a sonicator. The dye-loaded solution was then added to fill the cavity in the PDMS mold, and exposed to UV light (365 nm) for 10 minutes. After UV, the polymer was cross-linked. The shape of this polymer was the same as the embossed features of the template printed by the 3D printer. This dye-loaded polymer with the desired 3D geometric shape was then extracted from the mold and placed within a housing made of PLA. This housing was also printed using a 3D printer. The same polymer solution (e.g., the mixture of PNA, PETMP, EGDT, and the photoinitiator), but without any dye, was then added into the housing until it was filled (leaving about 0.5 mm space above the dye-loaded polymer). The housing was then placed under vacuum to remove air bubbles before exposure to UV light (365 nm) for 10 minutes. After curing, the process of fabricating the tablet was complete.
[0033] Results
[0034] Five different types of release profiles known to be clinically important were demonstrated: the constant, pulsed (e.g., five pulses), decreasing, and increasing profiles (
[0035] Release Rate as a Function of the Erodible Polymer
[0036] Materials and Methods
[0037] Two types of cross-linker were used to form the surface-eroding polymer: the pentaerythritol tetrakis (3-mercaptopropionate) (PETMP) or the ethylene glycol-based dithiol (EGDT). Because PETMP is a better cross-linker than EGDT, a higher ratio of PETMP was expected to result in a slower rate of erosion. A PETMP:EGDT ratio of 3 and 9 (i.e., 3:1 or 9:1 of PETMP:EGDT) were examined.
[0038] Results
[0039] The present study demonstrates that it is possible to change the duration of the release using different erodible polymers. Since the rate-limiting step involves the erosion of the polymer, varying the composition of the polymer can change the rate of erosion. FIG. 4 shows that when, e.g., the ratio of PETMP:EGDT is 3:1, the release is complete at 20-30 hours. In contrast, when the ratio the PETMP:EGDT ratio is 9:1, the release is complete at 50-80 hours. Notably, the release profiles are the same for both cases (one demonstrated for an increasing profileupper panel in
[0040] Release of More than One Agent from a Dosage Form
[0041] Materials and Methods
[0042] Two molds of the desired profiles were 3D printed, and two dye-containing polymers of their respective shapes were formed as described in the preceding examples. The two erodible polymers, each containing a dye, were placed together face-to-face, and placed in the 3D printed biodegradable housing (as shown in
[0043] Results
[0044] As demonstrated herein, multiple dyes can be released from a single dosage form (tablet), each dye releasable by its own unique release profile.
[0045] In conclusion, as demonstrated the present key present concepts of the tablet we fabricated: In conclusion, as demonstrated herein, the dosage forms of the present invention can be designed to 1) release drugs with any desired release profile, 2) release drugs with a desired duration of release and 3) release more than one drug simultaneously, each with their own unique and desirable release profile.
[0046] The relevant teachings of all patents, published applications and references cited herein are incorporated by reference in their entirety.
[0047] While this invention has been particularly shown and described with references to example embodiments thereof, it will be understood by those skilled in the art that various changes in form and details may be made therein without departing from the scope of the invention encompassed by the appended claims.
[0048] It should also be understood that, unless clearly indicated to the contrary, in any methods described herein that include more than one step or act, the order of the steps or acts of the method is not necessarily limited to the order in which the steps or acts of the method are recited.