Efforts
toward route evaluation and process optimization for the
preparation of brexpiprazole (1) are described. Starting
from commercially available dihydroquinolinone 11, a
three-step synthesis route composed of O-alkylation,
oxidation, and N-alkylation was selected for industry-oriented
process development aiming to reduce side reactions and achieve better
impurity profiles. The reaction conditions of the three steps were
investigated, and the control strategy for the process-related impurities
was established. The optimized process was validated on the kilogram
scale and now is viable for commercialization, with the results of
not less than 99.90% purity of 1 (by HPLC) and not more
than 0.05% of persistent impurities 15 and 16.