Physical vapor deposition was employed to prepare amorphous samples of indomethacin and 1,3,5-(tris)naphthylbenzene. By depositing onto substrates held somewhat below the glass transition temperature and varying the deposition rate from 15 to 0.2 nm/s, glasses with low enthalpies and exceptional kinetic stability were prepared. Glasses with fictive temperatures that are as much as 40 K lower than those prepared by cooling the liquid can be made by vapor deposition. As compared to an ordinary glass, the most stable vapor-deposited samples moved about 40% toward the bottom of the potential energy landscape for amorphous materials. These results support the hypothesis that enhanced surface mobility allows stable glass formation by vapor deposition. A comparison of the enthalpy content of vapor-deposited glasses with aged glasses was used to evaluate the difference between bulk and surface dynamics for indomethacin; the dynamics in the top few nanometers of the glass are about 7 orders of magnitude faster than those in the bulk at Tg - 20 K.

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A DSC method was developed for measuring the solubility of crystalline drugs in polymers. Cryomilling the components prior to DSC analysis improved the uniformity of the mixtures and facilitated the determination of dissolution endpoints. This method has the potential of providing useful data for designing physically stable formulations of amorphous drugs.

A remarkable property of certain glass-forming liquids is that a fast mode of crystal growth is activated near the glass transition temperature Tg and continues in the glassy state. This growth mode, termed GC (glass-crystal), is so fast that it is not limited by molecular diffusion in the bulk liquid. We have studied the GC mode by growing seven polymorphs from the liquid of ROY, currently the top system for the number of coexisting polymorphs of known structures. Some polymorphs did not show GC growth, while others did, with the latter having higher density and more isotropic molecular packing. The polymorphs not showing GC growth grew as compact spherulites at all temperatures; their growth rates near Tg decreased smoothly with falling temperature. The polymorphs showing GC growth changed growth morphologies with temperature, from faceted single crystals near the melting points, to fiber-like crystals near Tg, and to compact spherulites in the GC mode; in the GC mode, they grew at rates 3-4 orders of magnitude faster with activation energies 2-fold smaller than the polymorphs not showing GC growth. The GC mode had rates and activation energies similar to those of a polymorphic transformation observed near Tg. The GC mode was disrupted by the onset of the liquid's structural relaxation but could persist well above Tg (up to 1.15 Tg) in the form of fast-growing fibers. We consider various explanations for the GC mode and suggest that it is solid-state transformation enabled by local molecular motions native to the glassy state and disrupted by the liquid's structural relaxation (the alpha process).

An amorphous solid (glass) may crystallize faster at the surface than through the bulk, making surface crystallization a mechanism of failure for amorphous pharmaceuticals and other materials. An ultrathin coating of gold or polyelectrolytes inhibited the surface crystallization of amorphous indomethacin (IMC), an anti-inflammatory drug and model organic glass. The gold coating (10 nm) was deposited by sputtering, and the polyelectrolyte coating (3-20 nm) was deposited by an electrostatic layer-by-layer assembly of cationic poly(dimethyldiallyl ammonium chloride) (PDDA) and anionic sodium poly(styrenesulfonate) (PSS) in aqueous solution. The coating also inhibited the growth of existing crystals. The inhibition was strong even with one layer of PDDA. The polyelectrolyte coating still permitted fast dissolution of amorphous IMC and improved its wetting and flow. The finding supports the view that the surface crystallization of amorphous IMC is enabled by the mobility of a thin layer of surface molecules, and this mobility can be suppressed by a coating of only a few nanometers. This technique may be used to stabilize amorphous drugs prone to surface crystallization, with the aqueous coating process especially suitable for drugs of low aqueous solubility.

The crystallization of glasses and amorphous solids is studied in many fields to understand the stability of amorphous materials, the fabrication of glass ceramics, and the mechanism of biomineralization. Recent studies have found that crystal growth in organic glasses can be orders of magnitude faster at the free surface than in the interior, a phenomenon potentially important for understanding glass crystallization in general. Current explanations differ for surface-enhanced crystal growth, including released tension and enhanced mobility at glass surfaces. We report here a feature of the phenomenon relevant for elucidating its mechanism: Despite their higher densities, surface crystals rise substantially above the glass surface as they grow laterally, without penetrating deep into the bulk. For indomethacin (IMC), an organic glass able to grow surface crystals in two polymorphs (α and γ), the growth front can be hundreds of nanometers above the glass surface. The process of surface crystal growth, meanwhile, is unperturbed by eliminating bulk material deeper than some threshold depth (ca. 300 nm for α IMC and less than 180 nm for γ IMC). As a growth strategy, the upward-lateral growth of surface crystals increases the system's surface energy, but can effectively take advantage of surface mobility and circumvent slow growth in the bulk. C rystallization is a ubiquitous process, producing countless solids in the natural and man-made world. Glasses and amorphous solids are formed by avoiding crystallization while cooling liquids, condensing vapors, or drying solutions. The solidity of a glass might suggest resistance to crystallization; its very existence implies that crystallization is avoidable. And yet glasses can crystallize, sometimes surprisingly fast. The crystallization of glasses is of interest in many fields for understanding the stability of amorphous materials (1), the fabrication of glass ceramics, and the mechanism of biomineralization, for which crystallization of amorphous solid precursors is considered a key step (2).Recent studies have discovered that different modes of crystal growth can emerge as a liquid is cooled to form a glass (3-8), causing crystal growth fronts to advance at velocities much faster than predicted by standard theories. One such growth mode [the glass-to-crystal (GC) mode] exists in the bulk and can cause an increase of crystal growth rate by a factor of 10 4 with a temperature drop by a few kelvin (3, 4). Another new growth mode occurs at the free surface and can lead to much faster crystal growth than in the bulk (5-8). Although these phenomena have been observed prominently in organic glasses, they may be relevant for understanding glass crystallization in general. These phenomena seem to have counterparts in nonorganic glasses, but differences are also evident. Fast crystal growth is known for metallic glasses and amorphous silicon, but the abrupt activation of GC growth is reported only for organic glasses. Surface-enhanced crystal growth occurs in amorphous selenium ...

Abstract. We review recent progress toward understanding and enhancing the stability of amorphous pharmaceutical solids against crystallization. As organic liquids are cooled to become glasses, fast modes of crystal growth can emerge. One such growth mode, the glass-to-crystal or GC mode, occurs in the bulk, and another exists at the free surface, both leading to crystal growth much faster than predicted by theories that assume diffusion defines the kinetic barrier of crystallization. These phenomena have received different explanations, and we propose that GC growth is a solid-state transformation enabled by local mobility in glasses and that fast surface crystal growth is facilitated by surface molecular mobility. In the second part, we review recent findings concerning the effect of polymer additives on crystallization in organic glasses. Low-concentration polymer additives can strongly inhibit crystal growth in the bulk of organic glasses, while having weaker effect on surface crystal growth. Ultra-thin polymer coatings can inhibit surface crystallization. Recent work has shown the importance of molecular weight for crystallization inhibitors of organic glasses, besides "direct intermolecular interactions" such as hydrogen bonding. Relative to polyvinylpyrrolidone, the VP dimer is far less effective in inhibiting crystal growth in amorphous nifedipine. Further work is suggested for better understanding of crystallization of amorphous organic solids and the prediction of their stability.

A remarkable property of certain glass-forming liquids is that a fast mode of crystal growth is suddenly activated near the glass transition temperature, Tg, and continues in the glassy state. This mode of growth, termed GC (glass-crystal), is so fast that it is not limited by molecular diffusion in the bulk liquid. We have studied the GC growth by growing multiple crystal polymorphs from the liquid of ROY, currently the top system for the number of coexisting polymorphs of known structures. We observed a new feature of GC growth that conflicts with its current description in the literature. We found that the GC mode is not truly a new growth mode suddenly appearing near Tg but one already existing in the equilibrium liquid up to approximately 1.15 Tg, in the form of fast-growing fibers. This finding is relevant to testing different explanations for GC growth and favors the view that GC growth is enabled by molecular motions that are native to the glass but still persist in the viscous liquid.