Crystallization Design Institute

Our latest publication in the International Journal of Pharmaceutics (https://doi.org/10.1016/j.ijpharm.2025.126197) highlights the fact that “no product design without process design (control)”.

In this work, we are utilizing crystallization as a tool for product design in a proof-of-concept solution-based additive manufacturing approach to produce a solid dosage form inside a capsule carrier. By controlling the evaporative crystallization process the API crystallizes within a polymer matrix to generate a crystalline solid dispersion with polymorph control. The quality attributes of these dispersions have been tested and match those of commercially formulated tablets. This platform offers several advantages:
1. Eliminates known powder handling challenges of conventional multi-step solid dosage manufacturing.
2. Reduces the number of unit operations via process intensification.
3. Developed workflow and insights provide a generalizable approach applicable to other API – polymer – solvent systems, independent if crystalline or amorphous solid dispersion is needed.

Ultimately, our study is part of a three publication series that highlights efforts towards integrated end-to-end pharmaceutical manufacturing needed, e.g., for point-of-use manufacturing in remote areas or for personalized medicine through flexible (additive) formulation.

Thanks to all co-authors and collaborators:
Aliou Mbodji | Kelitsha Mulero Cruz | Andrea Arroyo Gomez | Cornelis Vlaar | Jorge Duconge | Jean-Christophe Monbaliu | Rose Cersonsky | Lian Yu | Geoff Zhang | Gerard Coquerel | Rodolfo Romanch | Torsten Stelzer

This work was supported by the National Aeronautics and Space Administration, the National Science Foundation (NSF) Wisconsin - Puerto Rico Partnership for Research and Education in Materials, as well as the UPR-UW PREM: Center for Advancing Research and Training for STEM Success.

The Crystallization Design Institute is thrilled to welcome Nathan Gallegos to the . Nathan is a fourth-year undergraduate student pursuing a bachelor’s degree in chemistry at the University of Puerto Rico, Rio Piedras Campus. At the CDI, he will work alongside Dr. Suresh Manivel, focused on Polymer-Based formulation development. In the near future, Nathan aspires to obtain a Ph.D. in forensic chemistry and continue research on the topic. Beyond laboratory work, he enjoys reading, relaxing with coffee, and just taking time to unwind with simple things. Welcome to , Nathan!