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The objective of this study is to compare three different feedstock powders for the binder jetting process by characterizing their flowability and sinterability. Binder jetting additive manufacturing is a promising technology for fabricating ceramic parts with complex or customized geometries. Granulation is a promising material preparation method due to the potential high sinterability and flowability of the produced powder. However, no study has been made to systematically compare raw and granulated powders in terms of their flowing and sintering behaviors. This paper aims at filling this knowledge gap. Two raw powders (i.e., fine raw powder of 300 nm and coarse raw powder of 70 μm) and one granulated powder from spray freeze drying were compared. Different flowability metrics, including volumetric flow rate, mass flow rate, Hausner ratio, Carr index, and repose angle were measured. Different sinterability metrics, including sintered bulk density, volume shrinkage, and densification ratio were compared for all three powders. Results show that granulated powder achieved comparably high flowability to that of the coarse raw powder and also comparably high sinterability to that of the fine raw powder. Moreover, suitable metrics for the characterization of the sinterability and flowability for these three powders are recommended. This study suggests spray freeze drying produces high-quality feedstock powder for binder jetting process.
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Room-Temperature Aerosol Dehydration of Green Fluorescent Protein
Rapid Room-Temperature Aerosol Dehydration (RTAD) is a novel, scalable drying technology for powderization and thermal stabilization of pharmaceutical drug products. Compared to conventional spray drying processes, typically using droplets of 10–200 lm in diameter generated by high-shear spraying, RTAD uses much smaller droplets with diameter 0.1 to 20 lm produced in modified liquid atomization processes. These fine droplets evaporate rapidly within 10–100 ms under room-temperature conditions, thereby reducing drying-induced stresses for thermally sensitive biologics. In this study, we used Green Fluorescent Protein (GFP) as a model biological molecule to optimize the design of the RTAD system and the process parameters. We experimentally investigated the effects of droplet size, multiphase flow patterns in the drying chamber, and application of polysorbate 20 as a model surfactant on GFP fluorescence after drying and powder reconstitution. The experiments demonstrated that the presence of surfactant in the formulation significantly influenced the GFP fluorescence intensity, especially for smaller droplets. The numerical studies using Computational Fluid Dynamics simulations revealed that the drying of droplets was dependent on the patterns of multiphase flow in the drying chamber, which can impact the intensity of GFP fluorescence in the produced dry powders. Non-axisymmetric flows and closed circulating streamlines near the drying gas inlet resulted in considerably longer particle residence times, which we infer means that GFP molecules were subjected to excess stress that negatively impacted the GFP fluorescence intensity. Through iterative optimization of the chamber design, process parameters and feedstock formulation, we achieved recovery of the GFP fluorescence intensity that exceeded 96% in the obtained dry powders. This work establishes GFP as a sensitive model biologic and its fluorescence intensity as a powerful tool to rapidly assess process efficiency and the ability to preserve bioactivity after dehydration. The study has broad implications for the design and scale-up of drying technologies, which can potentially transform the production of dry powder biopharmaceuticals.
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- PAR ID:
- 10660411
- Publisher / Repository:
- Taylor & Francis
- Date Published:
- Journal Name:
- Drying Technology
- Volume:
- 43
- Issue:
- 14
- ISSN:
- 0737-3937
- Page Range / eLocation ID:
- 2068 to 2082
- Subject(s) / Keyword(s):
- Biopharmaceutical processing Aerosol-assisted drying Particle engineering Spray drying Protein degradation
- Format(s):
- Medium: X
- Sponsoring Org:
- National Science Foundation
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- Free Publicly Accessible Full Text
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Accepted Manuscript
- Journal Article:
- https://doi.org/10.1080/07373937.2025.2569446
