Precision pharmaceutical 3D printing device
Provided herein are devices and systems for depositing a material or manufacturing a product, such as a pharmaceutical dosage form, by additive manufacturing. Further provided are methods of using the devices and systems, as well as methods of manufacturing a product, such as a pharmaceutical dosage form, by additive manufacturing. In certain embodiments, the device includes a material supply system configured to melt an pressurized a material, a pressure sensor configured to detect a pressure of the material within the device, and a control switch comprising a sealing needle operable in an open position and closed position. The sealing needle extends through a feed channel containing the material and includes a taper end, wherein the tapered end of the sealing needle engages a tapered inner surface of a nozzle to inhibit flow of the material through the nozzle when the sealing needle is in the closed position.
1. A method of manufacturing a pharmaceutical product by additive manufacturing, comprising:
melting and pressurizing a material;
flowing the material through an extrusion port of a nozzle comprising a tapered inner surface;
engaging a tapered end of a sealing needle with the tapered inner surface of the nozzle, thereby sealing the extrusion port and stopping flow of the melted material;
withdrawing the tapered end of the sealing needle, thereby resuming flow of the material through the extrusion port;
heating the material in a printing head comprising the nozzle using one or more heaters;
wherein a material supply system comprises a barrel and a feed channel connecting the barrel to the printing head; and
heating the material in the barrel, wherein the material is heated in the printing head to a temperature above the temperature of the material heated in the barrel.
2. The method of claim 1 , comprising receiving instructions for manufacturing the product.
3. The method of claim 1 , wherein:
the product is a pharmaceutical dosage form; and
the material is a pharmaceutically acceptable material.
4. The method of claim 3 , wherein the pharmaceutically acceptable material comprises a drug.
5. The method of claim 4 , wherein the pharmaceutical dosage form has a desired drug release profile.
6. The method of claim 3 , comprising receiving instructions for manufacturing the pharmaceutical dosage form.
7. The method of claim 3 , wherein the tapered end of the sealing needle is withdrawn to a selected open distance between a maximum open position and a closed position.
8. The method of claim 3 , comprising heating the material in a printing head comprising the nozzle using one or more heaters.
9. The method of claim 8 , wherein a material supply system comprises a barrel and a feed channel connecting the barrel to the printing head.
10. The method of claim 9 , further comprising heating the material in the barrel.
11. The method of claim 10 , wherein the material is heated in the printing head to a temperature above the temperature of the material heated in the barrel.
12. The method of claim 3 , wherein the tapered end of the sealing needle comprises a frustoconical tip.
13. The method of claim 3 , wherein the tapered end of the sealing needle comprises a pointed tip.
14. The method of claim 3 , wherein the material has a viscosity of about 100 Pa″s or more when extruded from the extrusion port.
15. The method of claim 3 , wherein the sealing needle is operable in an open position between a maximum open position and a closed position.
16. The method of claim 1 , comprising heating the material in a printing head comprising the nozzle using one or more heaters.
17. The method of claim 1 , wherein the material supply system comprises a barrel and a feed channel connecting the barrel to the printing head.
18. The method of claim 17 , further comprising heating the material in the barrel.
19. The method of claim 18 , wherein the material is headed in the printing head to a temperature above the temperature of the material heated in the barrel.
20. A method of manufacturing a pharmaceutical product by additive manufacturing, comprising:
melting and pressurizing a first material;
flowing the first material through a first extrusion port of a first nozzle comprising a tapered inner surface;
engaging a tapered end of a first sealing needle, thereby sealing the first extrusion port and stopping flow of the melted first material;
melting and pressurizing a second material; and
withdrawing a tapered end of a second sealing needle, thereby initiating flow of the second material through a second extrusion port.