ORS3-0022
Amphiphobic Interfaces for Solvent-Free Spherical Melt-Printing of Functional Polymer Microdepots
When and Where
Nov 30, -0001
12:00am - 12:00am
Presenter(s)
Dan Lewitus (Shenkar Engineering. Design. Art)
Co-Author(s)
Abstract
Advanced polymer processing increasingly relies on interfacial engineering to control morphology, encapsulation, and functionality at micro- and mesoscales. Inspired by the amphiphobic cuticle of the lotus leaf, we developed a solvent-free polymer processing platform in which molten polymers are deposited onto superoleophobic/superhydrophobic (amphiphobic) surfaces, inducing spontaneous self-shaping into highly uniform spherical microstructures.
In this spherical printing process, polymer melts are jetted onto amphiphobic substrates where wetting is suppressed and surface-tension forces drive controlled solidification into microspheres. Using polycaprolactone (PCL) as a model thermoplastic, we demonstrate high-precision melt-based fabrication of drug-loaded microdepots with >95% encapsulation efficiency, narrow size distributions, and tunable release profiles—without solvents, emulsifiers, or surfactants.
Two pharmaceutically relevant systems illustrate the versatility of this processing method. Ibuprofen was used as a small-molecule model to demonstrate processing-induced control of drug crystallization: by tuning droplet cooling rates and polymer–drug ratios, ibuprofen could be trapped in amorphous or co-crystalline states within the polymer matrix, enabling control over stability and release. Full-spectrum cannabis extracts were also incorporated into PCL microdepots by melt printing, yielding uniform solvent-free microspheres that provided sustained multi-component release, improved pharmacokinetics, and significant anticonvulsant effects in rat models.
This work establishes an interfacial-driven polymer microfabrication paradigm in which amphiphobic surface engineering replaces emulsification chemistry as the key tool for controlling particle shape, encapsulation, and solid-state organization, offering a scalable route to functional polymer microspheres for pharmaceuticals, nutraceuticals, and advanced materials.
In this spherical printing process, polymer melts are jetted onto amphiphobic substrates where wetting is suppressed and surface-tension forces drive controlled solidification into microspheres. Using polycaprolactone (PCL) as a model thermoplastic, we demonstrate high-precision melt-based fabrication of drug-loaded microdepots with >95% encapsulation efficiency, narrow size distributions, and tunable release profiles—without solvents, emulsifiers, or surfactants.
Two pharmaceutically relevant systems illustrate the versatility of this processing method. Ibuprofen was used as a small-molecule model to demonstrate processing-induced control of drug crystallization: by tuning droplet cooling rates and polymer–drug ratios, ibuprofen could be trapped in amorphous or co-crystalline states within the polymer matrix, enabling control over stability and release. Full-spectrum cannabis extracts were also incorporated into PCL microdepots by melt printing, yielding uniform solvent-free microspheres that provided sustained multi-component release, improved pharmacokinetics, and significant anticonvulsant effects in rat models.
This work establishes an interfacial-driven polymer microfabrication paradigm in which amphiphobic surface engineering replaces emulsification chemistry as the key tool for controlling particle shape, encapsulation, and solid-state organization, offering a scalable route to functional polymer microspheres for pharmaceuticals, nutraceuticals, and advanced materials.
