This study demonstrates the applicability
of terahertz time-domain
spectroscopy (THz-TDS) in evaluating the solid-state of the drug in
selective laser sintering-based 3D printed dosage forms. Selective
laser sintering is a powder bed-based 3D printing platform, which
has recently demonstrated applicability in manufacturing amorphous
solid dispersions (ASDs) through a layer-by-layer fusion process.
When formulating ASDs, it is critical to confirm the final solid state
of the drug as residual crystallinity can alter the performance of
the formulation. Moreover, SLS 3D printing does not involve the mixing
of the components during the process, which can lead to partially
amorphous systems causing reproducibility and storage stability problems
along with possibilities of unwanted polymorphism. In this study,
a previously investigated SLS 3D printed ASD was characterized using
THz-TDS and compared with traditionally used solid-state characterization
techniques, including differential scanning calorimetry (DSC) and
powder X-ray diffractometry (pXRD). THz-TDS provided deeper insights
into the solid state of the dosage forms and their properties. Moreover,
THz-TDS was able to detect residual crystallinity in granules prepared
using twin-screw granulation for the 3D printing process, which was
undetectable by the DSC and XRD. THz-TDS can prove to be a useful
tool in gaining deeper insights into the solid-state properties and
further aid in predicting the stability of amorphous solid dispersions.