MAGIC printheads are customizable multi-channel pneumatic systems for 3D printing that create precise pharmaceutical and biological micro-particles. They enable controlled mixing and extrusion, accommodate various materials, and enhance drug delivery and biomedical applications.
Producing micro- and nanoparticles for pharmaceutical and biological applications demands precise control over particle size, composition, and encapsulation efficiency to ensure effective drug delivery and therapeutic outcomes. Traditional fabrication methods, such as bulk mixing and conventional extrusion, often struggle with achieving uniformity and scalability, especially with sensitive biological materials like proteins, nucleic acids, and live cells. These methods are also inflexible accommodating diverse materials and the ability to maintain sterile conditions throughout the process.
Moreover, integrating real-time monitoring and control of critical parameters like temperature, pressure, and mixing dynamics remains a significant challenge, limiting the customization and optimization of particle properties. These obstacles inhibit the advancement of sophisticated drug delivery systems and the development of personalized therapeutic solutions.
MAGIC printheads are advanced multi-channel controlled pneumatic systems designed for extrusion-based 3D printing and particle fabrication in pharmaceutical and biological applications. They feature multiple linkers for seamless connections to printers and fluid reservoirs, allowing the integrated customizable functional setups such as microfluidic, coaxial, biaxial, or mixing configurations. Equipped with one or more nozzles, these printheads allow precise controlled extrusion, while various sensing and control elements like temperature and pressure sensors ensure optimal operating conditions.
Sterile housing maintains cleanliness during operations, and the printheads are fabricated using CAD software, 3D laser sintering or stereolithography, and optimized with flow simulation software. Operational parameters are highly adjustable, including pressures from 1 kPa to over 700 kPa and nozzle diameters ranging from 1 µm to 1000 µm, accommodating a wide array of materials such as biodegradable polymers, biological materials, and active pharmaceutical ingredients. Advanced features include customizable fluid paths, multiple mixing architectures, and the ability to link multiple printheads for complex operations.
What sets the MAGIC printhead system apart is its remarkable versatility and precision in particle fabrication, making it uniquely suited for pharmaceutical and biomedical applications. By combining extrusion-based 3D printing with emulsion and mixture evaporation techniques, the system achieves exceptional control over critical particle characteristics like size distribution, surface charge, morphology, and encapsulation efficiency.
Its customizable mixing architectures, which can incorporate stirrers, electric or magnetic fields, and intricate channel designs, enable the production of a diverse range of particles, including liposomes and lipid nanoparticles for mRNA delivery. The use of advanced simulation and rapid prototyping ensures optimized design and performance, while the system’s ability to handle sensitive materials through cryogenic collection surfaces enhances its applicability.
Comprehensive patent coverage further underscores its innovative methodology, distinguishing the MAGIC printheads as a leading technology in precise and controlled particle engineering.
https://patents.google.com/patent/WO2024026039A2/en?oq=+PCT%2fUS2023%2f028884