Particulate Atomisation Design Methods for the Development and Engineering of Advanced Drug Delivery Systems: A Review

The role and opportunities presented by particulate technologies (due to novel processing methods and advanced materials) have multiplied over the last few decades, leading to promising and ideal properties for drug delivery. For example, the dissolution and bioavailability of poorly soluble drug substances and achieving site- specific drug delivery with a desired release profile are crucial aspects of forming (to some extent) state-of-the-art platforms. Atomisation techniques are intended to achieve efficient control over particle size, improved processing time, improved drug loading efficiency, and the opportunity to encapsulate a broad range of viable yet sensitive therapeutic moieties. Particulate engineering through atomization is accomplished by employing various mechanisms such as air, no air, centrifugal, electrohydrodynamic, acoustic, and supercritical fluid driven processes. These driving forces overcome capillary stresses (e.g., liquid viscosity, surface tension) and transform formulation media (liquid) into fine droplets. More frequently, solvent removal, multiple methods are included to reduce the final size distribution. Nevertheless, a thorough understanding of fluid mechanics, thermodynamics, heat, and mass transfer is imperative to appreciate and predict outputs in real time. More so, in recent years, several advancements have been introduced to improve such processes through complex particle design coupled with quality by-design (QbD) yielding optimal particulate geometry in a predictable manner. Despite these valuable and numerous advancements, atomisation techniques face difficulty scaling up from laboratory scales to manufacturing industry scales. This review details the various atomisation techniques (from design to mechanism) along with examples of drug delivery systems developed. In addition, future perspectives and bottlenecks are provided while highlighting current and selected seminal developments in the field.