WO2017190994A1

WO2017190994A1 - Process for the manufacture of a solid pharmaceutical administration form

Info

Publication number: WO2017190994A1
Application number: PCT/EP2017/059849
Authority: WO
Inventors: Werner Stockum; Andreas Schindler; Sven VOGELGESANG; Daniel GOLDFUSS; Marc AUTENRIETH; Marc BERESHEIM
Original assignee: Merck Patent Gmbh
Priority date: 2016-05-02
Filing date: 2017-04-26
Publication date: 2017-11-09

Abstract

The present invention relates to a process for the preparation of a solid pharmaceutical administration form using a 3D laser printing process as well as to a composite layer usable in such process. The process is a contactless printing process that allows the production of solid pharmaceutical administration forms in a flexible manner and in conformity with the high quality standards required for the production of pharmaceuticals.

Description

Process for the manufacture of a solid pharmaceutical administration form

The present invention relates to a process for the preparation of a solid pharmaceutical administration form using a 3D laser printing process as well as to a composite layer usable in such process. The process is a contactless printing process that allows the production of solid

pharmaceutical administration forms in a flexible manner and in conformity with the high quality standards required for the production of

pharmaceuticals.

It is believed that future improvements in disease treatment is driven by point-of-care and home-based diagnostics linked with genetic testing and emerging technologies such as proteomics and metabolomics analysis. This has led to the concept of personalized medicine, which foresees the customization of healthcare to an individual patient.

Medication can be applied to the patient by using different

pharmaceutical formulations that are adapted to the desired application method, for example to oral (including buccal or sublingual), rectal, nasal, topical (including buccal, sublingual or transdermal), vaginal or parenteral (including subcutaneous, intramuscular, intravenous or intradermal) application. In general oral application is preferred as such application is easy and convenient and does not cause any harm that may be associated with other application methods such as parenteral application.

Pharmaceutical formulations usable for oral administration are, for example, capsules or tablets; powders or granules; solutions or

suspensions in aqueous or non-aqueous liquids; edible foams or foam foods; or oil-in-water liquid emulsions or water-in-oil liquid emulsions.

Tablets for oral administration are by far the most common dosage form, and are generally prepared by either single or multiple compressions (and in certain cases with moulding) processes. Tablets are usually prepared by using multiple process steps such as milling, sieving, mixing and

granulation (dry and wet). Each one of these steps can introduce difficulties in the manufacture of a medicine (e.g., drug degradation and form change), leading to possible batch failures and problems in

optimization of formulations.

Tablets are almost universally manufactured at large centralized plants via these processes using tablet presses essentially unchanged in concept for well over a century. This route to manufacture is clearly unsuited to personalized medicine and in addition provides stringent restrictions on the complexity achievable in the dosage form (e.g., multiple release profiles and geometries) and requires the development of dosage forms with proven long-term stability.

Use of 3D printing technology was proposed as an alternative approach to provide dosage forms as this potentially allows manufacture of personalized medicines at the point of care (Khaled S.A. et al. : Desktop 3D printing of controlled release pharmaceutical bilayer tablets, Int J Pharm 461 (2014) 105-1 1 1 ). Khaled et al. describes the printing of guaifenesin tablets by using an extrusion based 3D printer. According to this method a water based HPMC gel is prepared, filled into the printer head of an extrusion based 3D printer and printed. In such printing process a multitude of layers are placed successively on top of each other thereby forming the tablet. However, use of a gel like HPMC gel to prepare tablets is only feasible with active pharmaceutical ingredients (APIs) that are compatible with and stable in aqueous environment. Further, the solvent, especially the water that is present in the gel, has to be removed after printing which slow down the process flow. In addition, change of manufacturing from a tablet having as specific API to a different tablet with a different API requires extensive cleaning operations and extends setup times, especially as such manufacturing process has to meet the high quality standards (Good Manufacturing Practice (GMP)) that are

compulsory in the manufacturing of medicinal products.

Katstra W.E. et al. discloses 3D printing of a tablet using a so-called solid freeform fabrication (SFF) technique which employs powder processing wherein the tablet is build-up in a layer-wise manner (Katstra W.E. et al. : Oral dosage forms fabricated by Three Dimensional Printing, J Contr Rel 66 (2000) 1 -9). The process uses a 3D printer composed of a pair of horizontal -Vaxes that are suspended over a vertical piston, providing control over three directions of motion. For manufacture of tablet a thin layer of powder is spread onto a piston plate, droplets of a liquid binder solution are distributed over the powder bed through a nozzle that is moved back and forth and which provides binding of the powder particles together and generation of a 2D pattern. After lowering the piston by a fixed distance, another thin layer of powder is spread, and the process is repeated. However, the use of powder in process described by Katstra et al. is associated with formation of dust so that such process requires protective measures such as enclosed housing and dust extraction system. Further, the mechanical properties of the solid dosage forms, such as friability, might be critical in view of that the particles of the powder contained therein are only attached to each other by means of a binder and no compression step as it is used in conventional tableting processes is involved. In addition, change of manufacturing from a tablet having as specific active pharmaceutical ingredient (API) to a different tablet with a different API requires extensive cleaning operations to avoid cross contamination, especially in view of the formation of dust. To fulfill the compulsory high quality standards (Good Manufacturing Practice (GMP)) extended setup times are associated with such process.

Goyanes A. et al. describes 3D extrusion printing of a tablet using drug loaded a polymer (Goyanes A. et al. : Fused-filament 3D printing (3DP) for fabrication of tablets International, J Pharm 476 (2014) 88-92). In such method extruded filmaments of polyvinyl alcohol (PVA) are loaded with fluorescein sodium as model drug by incubation in an ethanolic fluorescein solution for 24 hours, dried in an oven and subsequently melt extruded in a 3D printer at 220Ό. However, the loading of PVA w ith API is time consuming, limits its applicability for APIs with different physicochemical properties and does not allow preparation of filmaments with high contents of API and finally no tablets with high drug content. In fact the diffusion driven loading step requires that the API must fulfill specific properties in terms of solubility and molecular size to be a suitable subject of such process. Further, the API must have a good thermal stability to be not destroyed at the high extrusion temperature (220°C) . As a result such process is applicable to a very limited number of APIs only, which are applied to the patient in low doses and that meet the very specific

physicochemical properties described above.

WO 2014/188079 discloses manufacturing of oral dosage forms of vitamin(s) and/or dietary mineral(s) or nicotine by inkjet printing. APIs are dissolved in mixtures of water and alcohols (propylene glycol, glycerol, ethanol), filtered and printed in squares of 1 cm x 1 cm on paper using an inkjet printer. However, such dosage forms are more two dimensional that is difficult to be handled by and administrated to the patient compared to three dimensional tablets. Further, due to the low mass of the dosage form, only dosage forms that contain very low dosages can be produced. In addition, the APIs must be soluble and stable in water / alcohol solutions.

All 3D printing processes that are described for the preparation of tablets and that are in principle usable for decentralized production of personalized solid dosage forms exhibit several disadvantages that hinder their broad applicability. Therefore, there is a strong demand for a process that overcomes such disadvantages. Especially a process is needed that does not require extensive setup times, that reduces cleaning operations to a minimum, that is applicable to a broad range of APIs in terms of their physicochemical properties and that is applicable also for APIs that are administrated to the patient in high dosage ranges (hundreds of milligrams to grams).

A process that meets such criteria is made available by the present invention. Such process uses a composite layer that comprises a laser energy absorbing layer and a layer that contains at least one active ingredient. The solid pharmaceutical administration form is build up by subsequent transfer of ingredient containing layer to one another by means of a laser beam.

With the aid of laser beams of various wavelength, it is possible to print and assemble successively layer on layer. The printing and assembling are carried out through the action of laser energy a) on the laser energy absorbing material itself (intrinsic reaction to generate heat increase and volume increase due to carbonization, foaming) and b) on the medium containing at least one active ingredient, which is transferred from the composite layer onto the assembling platform. If a laser beam of suitable energy and wavelength (for example Nd:Yag laser) hits a laser energy absorbing material and this is coated with a layer that contains an active ingredient, the active ingredient containing layer is transferred (printed) to the mounting plate, where it may be fixed thereon (e.g. by vacuum).

Repeating in this way, assembling of layer by layer to a 3D form (e.g. a tablet) is provided. The amount of laser energy absorbing material actually required for the printing and assembling depends on laser type, energy output, printing speed, layer thickness of laser energy absorbing layer, film material thickness and adhesion of active ingredient containing layer (and force to transfer), dwell time of assembling steps.

The present invention is directed to a process for the manufacture of a solid pharmaceutical administration form comprising at least one active ingredient comprising the steps

(a) positioning a composite layer (3) comprising a laser energy absorbing layer (1 ) and a layer that contains at least one active ingredient (2) between a plate (4) that is permeable for a laser beam that can be activated by a source of laser energy (5) and a mounting plate (6) whereat the layer of the composite containing at least one active ingredient (2) is positioned opposite to the source of laser energy (5) and is facing to the mounting plate (6);

(b) lowering the mounting plate (6) to shape an interspace (8) between the composite layer (3) comprising an active ingredient containing layer (2) and the mounting plate (6);

(c) transferring by action of laser beam from the source of laser energy (5) the active ingredient containing layer (2) of the composite (3) onto the mounting plate (6);

(d) repeating steps (a), (b) and (c) as often as needed to build up the solid pharmaceutical administration form;

(e) removing the solid pharmaceutical administration form from the mounting plate.

In an alternative embodiment of the present invention the mounting plate (6) comprises an area that is movable in vertical direction. When running the process in step (b) not the whole mounting plate is lowered but the movable area only. Accordingly, the present invention is also directed to a process for the manufacture of a solid pharmaceutical administration form comprising at least one active ingredient comprising the steps

(a) positioning a composite layer (3) comprising a laser energy absorbing layer (1 ) and a layer that contains at least one active ingredient (2) between between a plate (4) that is permeable for a laser beam that can be activated by a source of laser energy (5) and a mounting plate (6) comprising at least one area (7) that is movable in vertical direction (z axis) relative to the mounting plate whereat the layer of the composite containing at least one active ingredient (2) is positioned opposite to the source of laser energy (5) and is facing to the mounting plate (6);

(b) lowering the movable area (7) relative to the mounting plate (6) to shape an interspace (8^') between the composite layer (3) comprising an active ingredient containing layer (2) and the movable area (7) of the mounting plate (6);

(c) transferring by action of laser beam from the source of laser energy (5) the active ingredient containing layer (2) of the composite (3) into the interspace (8^') shaped by the movable area (7) that was lowered vertically relative to the mounting plate (6);

(e) removing the pharmaceutical administration form from the mounting plate.

Advantageously the movable area (7) in the mounting plate (6) is raised to the same level relative to the upper side of the mounting plate before the solid pharmaceutical administration form is removed.

The term "solid pharmaceutical administration form" as used herein means any pharmaceutical formulation that is solid and provides a dosage unit of an active pharmaceutical ingredient that can be administered to a patient by any way of application such as oral, rectal, vaginal, implantation. The solid pharmaceutical administration form can have any shape adapted to the application requirements, e.g. round, oval, rod like, torpedo shaped etc. Examples of solid pharmaceutical administration forms are tablets, pills, caplets, suppositories, implants.

The term "active ingredient" as used herein means any ingredient that provides a pharmacological or biological effect when applied to a biological system. The active ingredient may be a pharmaceutical drug, biological matter of viral or ling origin. Examples of an active ingredient that may be used in the process of the present inventions are insulin, heparin, calcitonin, hydrocortisone, prednisone, budesonide, methotrexate, mesalazine, sulfasalazine, amphotericin B, nucleic acids, or antigens (peptides, proteins, sugars, or other substances that form surfaces recognized by the immune system, either produced, extracted, or homogenized from tissue, an organism or a virus). The term "composite layer" as used herein means a layer comprising at least two layers that are attached to one another, each of said layers being comprised of a different material having a different function and

composition. In accordance to the present invention the composite layer comprises at least a laser energy absorbing layer and a layer that contains at least one active ingredient. Examples of further layers that can be present as part of the composite layer include separation layer(s) and adhesive layer(s) as defined and/or exemplified in this patent application.

The term "laser energy absorbing layer" as used herein means a layer that contains laser energy absorbing material as defined and/or exemplified in this patent application. The laser energy absorbing layer may be one layer, wherein an laser energy absorbing material is imbedded and/or distributed over the whole layer but also an assembly of layers comprising a layer that contains laser energy absorbing material (1 ^") that is covered on one or both sides with layer(s) (1 ^') and/or (1 ^"') that do not contain laser energy absorbing material (support layers).

The plate that is permeable for a laser beam is in fixed position relative to the mounting plate during the transfer (step (c)) and must have a sufficient mechanical strength to provide the back power needed for the transfer of the active ingredient containing layer in vertical direction relative to the surface of the laser permeable plate (downwards) to the mounting plate upon volume expansion of the composite layer that is triggered by the laser beam. The plate can consist of any material that is permeable for the laser beam and that has sufficient mechanical strength to provide the back power that is necessary for the transfer step. Suitable materials include glass such, for example, as quartz glass or borosilicate glass.

As used herein, "a" or "an" shall mean one or more. As used herein when used in conjunction with the word "comprising," the words "a" or "an" mean one or more than one. As used herein "another" means at least a second or more. Furthermore, unless otherwise required by context, singular terms include pluralities and plural terms include the singular. As used herein, "about" refers to a numeric value, including, for example, whole numbers, fractions, and percentages, whether or not explicitly indicated. The term "about" generally refers to a range of numerical values (e.g., +/- 1 -3% of the recited value) that one of ordinary skill in the art would consider equivalent to the recited value (e.g., having the same function or result). In some instances, the term "about" may include numerical values that are rounded to the nearest significant figure.

The shape of the solid pharmaceutical dosage form can be easily determined by simply controlling the irradiation area of the laser beam. The irradiation area, i.e. the area of the composite that is activated by the laser beam, defines the area of the active ingredient containing layer that is transferred by laser activation. By controlling the shape of the irradiation area active ingredient containing layer any desired shape, such as rectangular, quadratic, cruciform, circular or oval, can be transferred. By assembling drug containing layers with different shapes solid

pharmaceutical administration forms of any three-dimensional shape can be easily obtained. Compared to conventional tablet production the process of the present invention provides wide flexibility with respect to the shape the solid pharmaceutical administration form. Advantageously the shape of the solid pharmaceutical administration form can be easily adapted to various specific demands and, in addition, allows new shapes that cannot be made available by conventional tablet manufacturing processes.

The process of the invention uses layers containing the active ingredient. As the active ingredient is embedded in the layer it is not necessary to handle the pure active ingredient so that the problems associated with such handling are avoided. Active ingredient containing layers are simply attached to each another so that dust formation and contamination of working environment that would require protective measures such as enclosed housing and extensive cleaning operations is avoided. Further, solid pharmaceutical administration forms with different dosages and/or different active ingredients can be manufactured in an easy manner. For example solid pharmaceutical administration forms with different dosages but the same active ingredient can be manufactured by simply controlling the number of API containing layers that are attached to each other. Solid pharmaceutical administration forms with the same active ingredient but different release properties such as an administration form wherein a part of the active ingredient is released in an immediate release manner and another part of is released in a sustained release manner can be manufactured by assembling active ingredient containing layers having immediate release properties and active ingredient containing layers having sustained release properties. In a similar manner solid pharmaceutical administration forms with different active ingredients can be provided by assembling active ingredient containing layers wherein the different active ingredients are present as a mixture in the active ingredient containing layer and/or wherein the different active ingredients is present in different active ingredient containing layers. The latter is preferred if the active ingredients are incompatible to each other.

A switch from manufacturing of a solid administration form with a specific active ingredient to a different solid administration form with a different active ingredient can be performed by simply changing the composite layer comprising a layer that comprises one active ingredient to another composite layer that comprises another active ingredient without additional setup times. Solid pharmaceutical administration forms, wherein one administration form contains the same active ingredient with different release properties (such as immediate release plus sustained release) or wherein different active ingredients are present, that are incompatible to each other, can also be easily manufactured using the process of the present invention by subsequently using different composite layers (having different active ingredients and/or active ingredient releasing

characteristics) in the manufacture of that solid pharmaceutical administration form. The process of the present invention provides a maximum of flexibility and enables fast and easy operation without the need for time consuming cleaning operations and, therefore, is particularly suitable for the manufacture for personalized medication in a decentralized manner.

According to a preferred embodiment of the present invention the solid pharmaceutical administration form is fixed during assembling at the mounting plate or the movable area by a vacuum. Therefore, the invention is also directed to a process that is characterized in that a vacuum is applied via a vacuum chuck (9) to hold the solid pharmaceutical

administration form on the mounting plate (6) or its movable area (7) during its assembling.

The composite layer used in the process of the present invention can be a sheet or a tape. A tape is preferred as it can be easily handled and as it allows an easy positioning of it (step (a)) by using a roll to roll transport mechanism. Accordingly, the invention is also directed to a process that is characterized in that the composite layer (3) is provided as a tape (3^') and that the positioning of the composite layer (3) in step (a) is achieved by roll (1 1 ) to roll (1 1 ^') transport.

Advantageously the composite layer and the roll (1 1 ) to roll (1 1 ^') mechanism for its transport is integrated in a cassette (1 6) which allows easy handling of the composite layer and its use in the process of the present invention. Accordingly, the invention is also directed to a cassette (1 6) having a roll (1 1 ) to roll (1 1 ^') transport mechanism wherein such roll (1 1 ) to roll (1 1 ^') transport mechanism is equipped with the composite layer (3). Preferably the cassette comprises positioner rolls (4^'), (4^") which are moveable in up and down in vertical direction (z axis). This allows pressing / depressing of the composite layer (3) onto the mounting plate (6) depending from its status of operations. In a further preferred embodiment of the present invention the mounting plate is covered by a protection tape, which after completion of the manufacture of the pharmaceutical administration form is moved along the mounting plate to (x-axis) provide an empty place for assembling a new solid pharmaceutical administration form. Therefore, the present invention is further directed to a process that is characterized in that the mounting plate is covered by a protection tape (10) and that such protection tape (10) is moved after completion of the pharmaceutical administration form along the mounting plate (6) (x-axis) to provide an empty place for assembling a new solid pharmaceutical administration form. Advantageously the protection tape can be easily replaced (exchanged) against a new one to avoid cross-contamination of materials, especially of the active ingredients, when the manufacturing process is changed from one solid pharmaceutical administration form to another containing different active ingredient(s) and/or auxiliaries.

The protection tape can be made of any material that can be

manufactured as tape and that provides protection of mounting plate against contamination with material from the composite layer, especially the active ingredient containing layer. Preferably, the protection material is permeable to air so that a solid administration form placed on top of it can be fixed by applying a vacuum through the chuck below of it. A suitable material for a protection tape is virgin paper. If a protection tape is used as described above no cleaning operations are needed when switching the process of the present invention from the manufacturing of a solid pharmaceutical administration form to another solid pharmaceutical administration form that contains different active ingredient(s).

According to a preferred embodiment of the present invention, the protection tape is moved by using a roll to roll transport mechanism.

Therefore, the present invention is also directed to the process of the present invention that is characterized in that the protection tape (10) is moved by roll (12) to roll (12^') transport. The process of the present invention requires a composite layer that comprises a laser energy absorbing layer and a layer that contains at least one active ingredient. Accordingly, the present invention is also directed to a composite layer that is usable for the process of the invention comprising a laser energy absorbing layer (1 ) and a layer that contains at least one active ingredient (2).

According to an embodiment of the invention the laser energy absorbing layer of the composite layer comprises a laser energy absorbing material that is covered on one or both sides with support layer(s) of a plastic material. The plastic material isolates the laser energy absorbing material from the environment and the active ingredient containing layer and prevents contamination especially of the ingredient containing layer and the assembled solid pharmaceutical administration form. Therefore, the present invention is further directed to a composite layer which is

characterized in that the laser energy absorbing layer (1 ) comprises a layer comprising a laser energy absorbing material (1 ^") that is covered on one or both sides with support layers (1 ^'), (1 ^"') of a plastic material. In such embodiment support layers (1 ^') and/or (1 ^"') and the layer containing the laser energy absorbing material (1 ^") are bonded to one another as a unit. The support layers can be made of plastic material, wherein the material and/or thickness of layer (1 ^') can be the same or different to layer (1 ^"').

In an alternative embodiment of the invention the laser energy absorbing material is imbedded in the plastic material and distributed over the whole energy absorbing layer. Contamination of environment and the active ingredient layer by the laser energy absorbing material is prevented by its embedment in the plastic material. Thus, the present invention is further directed to a composite layer that is characterized in that the energy absorbing layer (1 ) consists of one layer, wherein a laser energy absorbing material is distributed within a plastic material.

Plastic material that is suitable for covering and/or embedding of the laser energy absorbing material that is present in the laser energy absorbing layer comprises polymers from the group of polyethylene (PE), polypropylene (PP), polyvinylchloride (PVC), polystyrol (PS),

polytetrafluorethylene (PTFE), poly(methyl methacrylate) (PMMA), polyacrylnitril (PAN), polyacrylamid (PAA), polyamide (PA), aramide (polyaramide), (PPTA, Kevlar®, Twaron®), poly(m-phenylen

terephthalamid) (PMPI, Nomex®, Teijinconex®), polyketons like

polyetherketon (PEK), polyethylene terephthalate (PET, PETE),

polycarbonate (PC), polyethylenglycol (PEG), polyurethane (PU), Kapton K and Kapton HN is poly (4,4'-oxydiphenylene-pyromellitimide),

Poly(organo)siloxane, Melamine-resin (MF). Accordingly, the present invention is as well directed to a composite layer that is characterized in that the plastic material is selected from the group of polymers from the group of polyethylene (PE), polypropylene (PP), polyvinylchloride (PVC), polystyrol (PS), polytetrafluorethylene (PTFE), poly(methyl methacrylate) (PMMA), polyacrylnitril (PAN), polyacrylamid (PAA), polyamide (PA), aramide (polyaramide), (PPTA, Kevlar®, Twaron®), poly(m-phenylen terephthalamid) (PMPI, Nomex®, Teijinconex®), polyketons like

polyetherketon (PEK), polyethylene terephthalate (PET, PETE),

Poly(organo)siloxane, Melamine-resin (MF).

The plastic material can be processed to layers using the methods known in the art such as, for example, by polymer extrusion, casting, calendaring and blow molding. Using such methods layers without laser energy absorbing material (support layers) and as well as the layer that contain laser energy absorbing material can be prepared and made available.

The term "laser energy absorbing material" as used herein means any material that absorbs laser light and converts it to some extend to heat. In principle, any laser energy absorbing material can be used in the present invention. Laser energy absorbing materials that are especially suitable for the present invention are indium oxide, indium tin oxide (ITO), antimon tin oxide (ATO), antimon oxide, tin oxide, zinc oxide, aluminium zinc oxide (AZO), a mixture of metal oxides, zinc sulfide, tin sulfide, carbon black, graphite, metal oxides, silicates, metal oxide coated mica or Si02 flakes, a conductive pigment, sulfides, phosphates, BiOCI, anthracene, perylenes, rylenes, pentaerythritol or a mixture of two or more materials thereof.

Therefore, the present invention is also directed to a composite layer that is characterized in that the laser energy absorbing material is indium oxide, indium tin oxide (ITO), antimon tin oxide (ATO), antimon oxide, tin oxide, zinc oxide, aluminium zinc oxide (AZO), a mixture of metal oxides, zinc sulfide, tin sulfide, carbon black, graphite, metal oxides, silicates, metal oxide coated mica or SiO2 flakes, a conductive pigment, sulfides, phosphates, BiOCI, anthracene, perylenes, rylenes, pentaerythritol or a mixture of two or more materials thereof.

The laser energy absorbing material can be present in the laser energy absorbing layer in any particle size that is processible and that provides heat generation and distribution suitable for running the process. According to a preferred embodiment of the invention the composite layer is characterized in that the laser energy absorbing material present in the energy absorbing layer has a mean particle diameter from about 50nm to about 150nm.

The laser energy absorbing material can be present in the laser energy absorbing layer in any quantity that that is sufficient to provide the heat in an amount that is suitable for running the process. According to a preferred embodiment of the invention the composite layer is characterized in that the laser energy absorbing layer (1 ) comprises 0.01 -20% by weight of laser energy absorbing material.

The process of the present invention is based on a volume expansion of the laser energy absorbing layer and heat generation of the laser energy absorbing material as a result of activation of a laser beam, that both lead to the transfer of the active ingredient containing layer to the mounting plate or the movable area of the mounting plate. Volume expansion arises from foaming of the plastic material that is present in the laser energy absorbing layer and that is induced from heat and gas formation, especially

carbonization (CO2 formation) in the plastic material, and freezing of the generated foam upon subsequent cooling. Volume increase can be facilitated by the presence of copolymers of ethylene/ethylene acrylate, epoxy resins, polyesters, polyisobutylene, polyamides, polystyrene, acrylic polymers, polyamides, polyimides, melamine, urethane, benzoguanine and phenolic resins, silicone resins, micronized cellulose, fluorinated polymers (PTFE, PVDF inter alia) and micronized wax as filler or mixtures thereof which decompose and gives volume increase due to foaming, gas release and freezing. Accordingly, the present invention is invention is further directed to a composite layer that is characterized in that laser energy absorbing layer (1 ) contains copolymers of ethylene/ethylene acrylate, epoxy resins, polyesters, polyisobutylene, polyamides, polystyrene, acrylic polymers, polyamides, polyimides, melamine, urethane, benzoguanine and phenolic resins, silicone resins, micronized cellulose, fluorinated polymers (PTFE, PVDF inter alia) and micronized wax as filler or mixtures thereof.

The polymers for facilitating volume increase are admixed to the plastic material for embedding the laser energy absorbing material. They can be dissolved, for example by melt extrusion, in the plastic material to form a homogeneous material with the plastic material for embedding the laser energy absorbing material or admixed and maintained as particles within the such plastic material. If admixed and maintained as particles the polymers for facilitating volume increase preferably have mean particle sizes in the range from aboutI O nm to about 20 μηι.

Although the plastic material present in the energy absorbing layer isolates and/or imbeds the laser energy absorbing material from the active ingredient containing layer and prevents it from contamination with the laser energy absorbing material it can be desirable to further separate the energy absorbing layer from the active ingredient containing layer. Beside additional prevention of the active ingredient containing layer from contamination a layer separating the energy absorbing layer from the active ingredient containing layer may improve the properties of the composite layer that are required for its use in the process of the present invention. For example it may improve detachment characteristics of the active ingredient containing layer from the composite layer at the transferring step (step (c)). Therefore, the present invention is also directed to a composite layer that is characterized in that it comprises a separation layer (13), which is located between the energy absorbing layer (1 ) and the layer that contains at least one active ingredient (2).

The separation layer can be made from any material that can be processed to a layer and can be attached to the laser energy absorbing layer and the active ingredient containing layer and that provides the required properties such as suitable detachment properties. Suitable materials comprises saccharides, like disaccharides such as sucrose or lactose, polysaccharides such as starch, cellulose or derivatives thereof, modified celluloses such as microcrystalline cellulose and cellulose ethers, such as hydroxypropyl cellulose (HPC), croscarmellose sodium, sugar alcohols such as xylitol, sorbitol or maltitol, glucose, proteins such as gelatin, synthetic polymers such as polyvinylpyrrolidone (PVP), cross linked polyvinyl N-pyrrolidone or polyethylene glycol (PEG), poloxamer,

Tragacanth, Gummi Arabicum, a low melting waxes such as beeswax, candelilla wax, carnauba wax, ceresine wax, microcrystalline wax, ozokerite wax, magnesium stearate, paraffin wax and combination thereof.

Therefore, the invention is also directed to a composite layer that is characterized in that the separation layer (13) comprises at least a saccharide, which can be a disaccharide such as sucrose or lactose, a polysaccharide such as starch, cellulose or a derivative thereof, a modified cellulose such as a microcrystalline cellulose or a cellulose ether, such as hydroxypropyl cellulose (HPC), croscarmellose sodium, a sugar alcohol such as xylitol, sorbitol or maltitol, glucose, a protein such as gelatin, a synthetic polymer such as polyvinylpyrrolidone (PVP), cross linked polyvinyl N-pyrrolidone or polyethylene glycol (PEG), poloxamer, Tragacanth, Gummi Arabicum, a low melting wax such as beeswax, candelilla wax, carnauba wax, ceresine wax, microcrystalline wax, magnesium stearate, ozokerite wax or paraffin wax and combinations thereof. The separation layer can have a thickness from 2 μηι to 150 μηπ, preferably from 5 μηι to 100 μηπ, more preferably from 10 μηι to 30 μηι and most preferably from 10 μηι to 20 μηπ, especially of about 17 μηι.

Depending from the requirements of the active ingredient present in the active ingredient containing layer and the desired release properties of the solid pharmaceutical administration form it may be difficult in some cases to provide an active ingredient containing layer that has the physicochemical characteristics, especially the adhesive properties, that are required for sufficient attachment of the active ingredient containing layers one to another during assembling in the process of the present invention. In such cases an additional layer with adhesive properties, i.e. an adhesion layer, can be placed on the active ingredient containing layer located outward and opposite to the energy absorbing layer of the composite. Accordingly, the present invention is as well directed to a composite layer that is

characterized in that it comprises an adhesion layer (14) which is located outward and opposite to the energy absorbing layer (1 ). In the transfer step (step (c)) the adhesion layer is detached from the laser energy absorbing layer and transferred to the mounting plate or the movable area on it together with the active ingredient containing layer.

Materials that can be used for an adhesion layer can be any material that can be used as auxiliaries in pharmaceutical administration forms and that provide the required adhesive properties. Materials that can be used for the adhesion layer comprise methyl cellulose, liquid glucose, tragacanth, ethyl cellulose, gelatin, hydroxy propyl methyl cellulose (HPMC), starch paste, hydroxy propyl cellulose, pregelanized starch, sodium carboxy methyl cellulose, algenic acid, polyvinyl pyrollidone (PVP), cellulose, gummi arabicum, polyethylene glycol (PEG) and combinations thereof. Therefore, the invention is further directed to a composite layer that is characterized in that the adhesion layer (14) comprises methyl cellulose, liquid glucose, tragacanth, ethyl cellulose, gelatin, hydroxy propyl methyl cellulose

(HPMC), starch paste, hydroxy propyl cellulose, pregelanized starch, sodium carboxy methyl cellulose, algenic acid, polyvinyl pyrollidone (PVP), cellulose, gummi arabicum, polyethylene glycol (PEG) or combinations thereof.

The terms "layer containing at least one active ingredient" and "active ingredient containing layer" as used herein are used synonymous and both means a layer that contains at least one active ingredient. Beside the active ingredient suitable auxiliaries are present in the layer to provide a matrix for the distribution of the active ingredient and to provide the framework and properties that are required for their manufacture for the active ingredient containing layer, its use in the process of the present invention and the stability and release properties of active ingredient after application of the solid pharmaceutical dosage form to the patient. The layer containing at least one active ingredient usually is a continuous uninterrupted layer. Alternatively, however, the layer containing at least one active ingredient also encompass a layer, wherein the layer is divided in multitude of pieces with defined geometry (2^'), (19e) - (19i), (20a) - (20h), (e.g. squares, rectangles, hexagons etc.) that are separated from each other by another layer, such as, for example, the laser energy absorbing layer (1 ) or a support layer (1 ^"'). An active ingredient containing layer, wherein the layer is divided in a multitude of pieces can be provided by first providing a laser energy absorbing layer (1 ) with engraved cavities (1 ^"") having a defined geometry for shaping the geometry of the pieces and subsequent filling the cavities in the energy absorbing layer with the material constituting the active ingredient containing layer, for example by using a doctor blade. The active ingredient containing layer can have a thickness from 5 μηι to 1000 μηπ, preferably from 10 μηι to 500 μηπ, more preferably from 30 μηπ to 200 μηπ and most preferably from 50 μηι to 100 μm, especially of about 70 μηι.

If a composite layer (3) that comprises an active ingredient containing layer that is formed as a continuous uninterrupted layer (2) is used in the process of the invention solid pharmaceutical administration forms are manufactured that consist of a continuous uniform body. If a composite layer is used, wherein the layer containing at least one active ingredient is divided in a multitude of pieces solid pharmaceutical administration forms can be manufactured that either have a closed structure or have an open structure as exemplified in Figures 22 and 23 respectively. Dissolution and release of active ingredient from a solid pharmaceutical administration form depends, i.a. from its geometry and the surface that is exposed to the environment after application. Therefore, changing the shape and surface area of the solid pharmaceutical formulation that is exposed to dissolution after its application by using composite layers that comprise a layer containing at least one active ingredient that is divided in a multitude of pieces and by variation of their arrangement during assembling of the active ingredient containing layers to the solid pharmaceutical

administration form offers a good opportunity to adapt the dissolution / release properties of the solid pharmaceutical administration form to the needs. Therefore, the invention is also directed to a composite layer that is characterized in that the layer containing at least one active ingredient that is divided in a multitude of pieces (2^'). The term "a multitude of" or

"multiple" as used herein means at least 9 pieces per cm². According to suitable embodiments the layer containing at least one active ingredient is divided in into 10-20, 20-1000 or 1000-10000 pieces per cm².

According to a further appropriate embodiment of the invention the layer containing at least one active ingredient that is divided in a multitude of pieces (2^') is patterned with a square shape and/or rectangular shape and/or round shape and/or oval shape. According to an further appropriate embodiment of the invention the layer containing at least one active ingredient that is divided in a multitude of pieces (2^') consists of multiple squares with edge length of 10μηι up to 2500μηπ, or multiple round dots with diameter of 10 μηι up to 3000 μηι and gap to adjacent squares of 10 μηι up to 2000 μηι.

The process of the present invention can also be used for the

manufacture of a solid pharmaceutical administration form that comprises an active ingredient containing layer that is surrounded by a layer that does not contain an active ingredient thereby forming a core-shell structure. In such embodiment the active ingredient containing layer is divided in a multitude of pieces (2^') and the layer that does not contain an active ingredient is divided in a multitude of pieces (2^") as well. In alternative embodiments the shell contains the same active ingredient in a different amount, such as, for example in a higher dosage that is rapidly released upon after administration of the solid pharmaceutical dosage by the patient form due to the first dissolution of the (outer) shell that builds up an initial high API level in the blood prior to release and absorption of the same API from the core, or a different active ingredient, which after administration of the solid pharmaceutical dosage form by the patient due to the first dissolution of the (outer) shell is released first and prior to the release of the

(different) API present in the core thereby achieving subsequent and time controlled release and absorption of different APIs. Embodiments of a solid pharmaceutical administration form having such a core shell structure as exemplified in Figures 30 to 33. Dissolution and in-vivo release profile of active ingredient of the core- shell structure can be varied over a wide range depending from the demands. For example, adjustment of the dissolution and in-vivo release profile can be performed by careful selection of the material that builds up the shell of the system (e.g. enteric coating such as Eudragit L 100-55 or polyvinyl acetate phthalate or non-enteric coating such as hydroxyethyl cellulose) and/or the thickness of the shell material. The process of the present invention allows also the manufacture of more complex systems such as core-shell structures with more than one shells wherein the core-shell structure is surrounded by one or more additional shells attached to each other. Depending from the demands the inner shells but also the outer shell may contain one or more active ingredients whereby the active ingredient may be the same or different ones. By applying this principle various solid pharmaceutical dosage forms can be provided from which the active ingredient/s is/are released in a predetermined manner according the specific demands.

The process of the present invention also allows the exact placement of communication device within the solid pharmaceutical administration form. A communication device may be used in the solid pharmaceutical administration form to give information on the position and/or condition of the composite layer in the body after oral intake by the patient. For example information on its position within the gastrointestinal tract over the time and/or on the time when the composite layer is disintegrates and the active ingredient is released may be given. Examples of communication devices that can be placed in the solid pharmaceutical administration form are a RFID (Radio Frequency Identification) tag, an electromagnetic signaling device, a magnetic device, an infrared emitting device or an ultrasonic device. Preferably the communication device is a RFID tag. RFID tracking ingestion of medication can be also used to detect proper use of medication.

Depending from the information to be provided the communication device can be placed at any position of each layer of the solid

pharmaceutical administration form. In the following some embodiments are shown, wherein one or more RFID tag(s) (2^"') is/are placed in a solid pharmaceutical administration form that is arranged as core shell system (Figures 31 to 33). Of course RFID tags can be placed also to any other place within the respective arrangement. Suitable auxiliaries that can be used as material for the active ingredient containing layer are all auxiliaries that are known in the art that provide a structure and properties that are necessary and that are suitable as auxiliaries for pharmaceutical administration forms. Such auxiliaries include, for example, matrix building polymers, such as, for example, polyvinyl pyrrolidone or hydroxypropyl cellulose, disintegrants, such as, for example, carboxymethylcellulose sodium, croscarmellose sodium, surfactants, such as, for example, benzalkonium chloride or cetrimide, adhesives, such as, for example, polymethacrylates, tackifiers, such as, for example, poly (β-pinene), etc. As an example, the material for the active ingredient containing layer can be a mixture of a high concentrated mixture of active ingredient, binders, fillers and adhesives from the list: Talkum, Magnesium carbonate, Methyl Cellulose, Liquid Glucose, Tragacanth, Ethyl Cellulose, Gelatin, Hydroxy Propyl Methyl Cellulose (HPMC), Starch Paste, Hydroxy Propyl Cellulose, Pregelanized Starch, Sodium Carboxy Methyl Cellulose, Algenic Acid, Polyvinyl Pyrollidone (PVP), Cellulose, Gummi Arabicum, Polyethylene Glycol (PEG).

According to an appropriate embodiment of the invention the layer containing at least one active ingredient that is present in the composite layer comprises the active ingredient in an amount from 0.1 % to 97% by weight.

According to an appropriate embodiment of the invention the layer containing at least one active ingredient that is present in the composite layer comprises no more than 25% moisture.

According to a further embodiment of the invention the layer containing at least active ingredient (2) that is present in the composite layer comprises a sweetener selected from the group consisting of sucrose, dextrose, fructose, xylitol, sorbitol, mannitol, levulose, corn syrup solids, and combinations thereof. According to a further suitable embodiment of the invention the layer containing at least active ingredient (2) that is present in the composite layer comprises a plasticizer selected from the group consisting of glycerin, glycerol monostearate, acetylated monoglycerides, lecithin, vegetable oils, and combinations thereof.

As described above the composite layer is preferably used in the process of the present invention in the form of a tape, which can be easily handled in the process using a roll to roll transport system. To improve and simplify the handling of the composite layer in the process the composite layer can be provided in recoiled form in a roll dispenser. If recoiled in a dispenser the composite layer is protected against physical damage and other harmful environmental influences and can be easily transported and stored. When the composite layer is needed to be used in the process it can easily be made available, for example by using a simple docking mechanism that connects the dispenser with the manufacturing equipment. Accordingly, the present invention is also directed to the composite layer of the present invention that is characterized in that it is provided in a recoiled form in a roll dispenser (1 1 ^").

Composite layer (3) can be prepared using a multiple process steps that includes mixing and coating steps and includes various techniques known in the art such as extrusion and/or lamination techniques.

For example, mixing of materials of that are contained in one layer (e.g. laser energy absorbing material and a plastic material or laser energy absorbing material, a plastic material and a polymer that facilitates volume increase upon activation by laser beam that constitutes the laser energy absorbing layer or the ingredients that are contained in the active ingredient containing layer, the adhesion layer or the separation layer) can be performed by using appropriate mills such as, for example, a high speed mixer or a roll mixer. In principle composite layer is prepared by successively applying one layer to another layer until the final composite is built up. For example, a composite layer according to Figure 4 or 5 is manufactured by applying the active ingredient containing layer (1 ) to the laser energy absorbing layer (2) and a composite layer according to Figure 8 is prepared by first applying the separation layer (13) to the laser energy absorbing layer (2), then applying active ingredient containing layer (1 ) the separation layer and finally applying the adhesive layer (14).

The techniques that can be used for applying one layer to the other can be any method known in the art, such as, for example, coating techniques using a doctor blade, melt extrusion coating and various printing

techniques, e.g. screen printing, stencil printing, silk-screen printing, pad printing, stamp printing, gravure printing, mikrojet-printing and ink-jet printing. Depending from the technique further steps can be necessary, such as a drying step after coating with a doctor blade or cooling after melt extrusion. Screen printing, silk-screen printing, pad printing, stamp printing, gravure printing, mikrojet-printing and ink-jet printing are preferred methods for applying one layer to another to form the composite layer (3).

Usually the manufacture of the composite starts with providing the laser energy absorbing layer (1 ). Such laser energy absorbing layer can be prepared by homogeneous distribution of the laser energy absorbing material (e.g. carbon black, ATO) in the plastic material and subsequent film manufacturing with extrusion (e.g. blown film extrusion). If the laser energy absorbing layer (1 ) contains one or to support layers (1 ^') and/or (1 ^") such layer(s) can be applied to it by lamination, e.g. by using a roll laminator.

In an example preparation of the composite layer (3) includes multiple process steps starting with the mixing process for the laser energy absorbing material. Homogeneous distribution during the mixing step of selected raw materials is achieved, for example, with high speed dissolver and/or 3 roll mill. Coating of the laser energy absorbing layer onto a polymer film with defined thickness is feasible with doctor blade technique or a printing process. A convection oven or belt furnace is used for drying of the coated substrates. The dry laser energy absorbing layer will be complete encapsulated due to lamination of a second polymer film on top. Another mixing step is used for the active ingredient vehicle with high speed dissolver and 3 roll mill. Coating of the active ingredient layer onto the composite layer (1 ) with defined thickness and pattern is feasible with a printing process (e.g. screen printing or stencil printing).

The invention is illustrated in the Figures.

FIGS. 1 A to 1 D shows the configuration and the process steps (a), (b) and (c) of the process of the present invention in accordance to Claim 1 using a composite layer (3). The configuration differs from the configuration of FIG. 2 in that it does not comprise a movable area of the mounting plate (6). Instead the whole mounting plate can be moved down (in z-axis).

Further it comprises a protection tape (10) that is arranged underneath the composite layer (3) and can be moved by a roll to roll system (12), (12^').

The composite layer (3) is positioned onto the mounting plate (6) and fixed above the mounting plate (6) with a glass plate (4) (step (a)). The mounting plate (6) is moved down (z-direction) to provide a gap (8) having the same thickness as the active ingredient containing layer (FIG 1 A). The programmed laser (5) is activating the transfer step of the layer that contains at least one active ingredient (2) onto the mounting plate (6) (step (c)) (FIG 1 B). After transfer of the first layer that contains at least one active ingredient (2) onto the mounting plate (6) the composite layer (3) is moved along the x-axis and/or y-axis to provide new active ingredient containing layer above the (first) layer on the mounting plate (6) and steps (b) and (c) are repeated (FIGS 1 C and D). Positioning of new active ingredient containing composite layer (3) above the assembled layers on the mounting plate (step (a)) and steps (b) and (c) are repeated as often as needed to assemble the solid pharmaceutical administration form.

Adherence of the active ingredient containing layer(s) on the mounting plate (6) can be supported by applying a vacuum at the vacuum chuck (9). After complete assembly the solid pharmaceutical administration form it can be moved by moving the protection tape (10) along the x-axis by activating of the roll to roll system (12), (12^') and is removed (step (e)).

FIGS. 2 A to 2 D show the configuration and the steps (a), (b) and (c) of the process of the present invention in accordance to Claim 2 using a composite layer (3). The composite layer (3) is positioned onto the movable area (7) of the mounting plate (6) and fixed above with a glass plate (4) (step (a)). An area of the mounting plate (6) is moved down to provide a gap (8^') having the same thickness as the active ingredient containing layer (step (b)) (FIG 2 A). The programmed laser (5) is activating the transfer step of the layer that contains at least one active ingredient (2) onto the movable area (7) of the mounting plate (6) (step (c)) (FIG 2 B). After transfer of the first layer that contains at least one active ingredient (2) onto movable area (7) of the mounting plate (6) the composite layer (3) is moved along the x-axis and/or y-axis to provide new active ingredient containing layer above the (first) layer on movable area (7) of the mounting plate (6) and steps (b) and (c) are repeated (FIGS 2 C and D). Positioning of new active ingredient containing composite layer (3) above the assembled layers on the movable area (7) of the mounting plate (6) (step (a)) and steps (b) and (c) are repeated as often as needed to assemble the solid pharmaceutical administration form. Adherence of the active ingredient containing layer(s) on movable area (7) of the mounting plate (6) can be supported by applying a vacuum at the vacuum chuck (9). After complete assembly the solid pharmaceutical administration form is removed (step (e)). Advantageously the movable area (7) in the mounting plate (6) is raised to the same level relative to the upper side of the mounting plate before the solid pharmaceutical administration form is removed.

FIG. 3 shows an advantageous configuration that can be used for the process of the present invention, wherein with a composite layer (3) is provided as a tape (3^') and transported by roll to roll dispensing system (1 1 ), (1 1 ^'). The mounting plate (6) is movable in z-direction and sheeted by a protection tape (10), which is movable along x-axis by activation of another roll to roll system (12), (12^'). The programmed laser (5) is activating the print step of the active ingredient onto the mounting plate (6). During assembling the solid pharmaceutical administration form is fixed is fixed by a vacuum chuck (9).

FIG. 4 shows a composite layer (3) consisting of a laser energy absorbing layer (1 ) and a layer that contains at least one active ingredient (2), wherein the laser energy absorbing layer (1 ) comprises a layer comprising the laser energy absorbing material (1 ^") that is covered on both sides with support layers (1 ^') and (1 ^"') that does not contain laser energy absorbing material and that are transparent and stable to laser light.

FIG. 5 shows a composite layer (3) consisting of an energy absorbing layer (1 ) that consists of one layer, which contains a laser energy absorbing material, and a layer that contains at least one active ingredient (2).

FIG. 6 shows a composite layer (3) as in FIG. 4, wherein a separation layer (13) is present between a support layer (1 ^"') and the layer that contains at least one active ingredient (2).

FIG. 7 shows a composite layer (3) as in FIG. 5, wherein a separation layer (13) is present between the laser energy absorbing layer (1 ) and the layer that contains at least one active ingredient (2).

FIG. 8 shows a composite layer (3) as in FIGS. 6, wherein an adhesion layer (14) is present on the bottom side of the layer that contains at least one active ingredient (2). FIG. 9 shows a composite layer (3) as in FIG. 7, wherein an adhesion layer (14) is present on the bottom side of the layer that contains at least one active ingredient (2).

FIG. 10 shows a composite layer (3) as in FIG. 4, wherein an adhesion layer (14) is present on the bottom side of the layer that contains at least one active ingredient (2). FIG. 1 1 shows a composite layer (3) as in FIG. 5, wherein an adhesion layer (14) is present on the bottom side of the layer that contains at least one active ingredient (2).

FIG. 12 shows a composite layer (3) consisting of a laser energy absorbing layer (1 ) consisting of a layer with a laser energy absorbing material (1 ^") and a support layer (1 ^"'), a separation layer (13) and a layer that contains at least one active ingredient (2).

FIG. 13 shows a composite layer (3) as in FIG. 12, wherein an adhesion layer (14) is present on the bottom side of the layer that contains at least one active ingredient (2).

FIG. 14 shows a composite layer (3) as in FIG. 12 but without a separation layer (13).

FIG. 15 shows a composite layer (3) as in FIG. 14, wherein an adhesion layer (14) is present on the bottom side of the layer that contains at least one active ingredient (2).

FIG. 1 6 shows a composite layer (3) consisting of a support layer (1 ^') a layer comprising a laser energy absorbing material (1 ^") and a layer that contains at least one active ingredient (2) at the bottom side.

FIG. 17 shows a composite layer (3) as in FIG. 1 6, wherein a separation layer (13) is present between the layer comprising the laser energy absorbing material (1 ^") and the layer that contains at least one active ingredient (2).

FIG. 18 A shows an advanced variant of the composite layer comprising a laser energy absorbing layer (1 ) consisting of a support layer (1 ^'), a layer comprising a laser energy absorbing material (1 ^") and a support layer (1 ^"'), wherein the support layer (1 ^"') has engraved cavities (1 ^"") that can be filled with material containing at least one active ingredient and that constitute the pieces (2^') of the layer comprising at least on active ingredient. FIG 18 B shows such composite layer (3), wherein the cavities (1 ^"") are filled with material containing at least one active ingredient and constitute the pieces (2^') of the layer comprising at least on active ingredient. The layer containing at least one active ingredient is divided in a multitude of pieces (2^'). Cavity size depth can be from 50 μηι up to 500 μηι (18 A). Cavity size diameter can be 50 μηι up to 5 mm.

FIG. 19 shows the bottom side of a composite layer (3) with square sized cavities arranged in 5 different rows, wherein such cavities are filled or imprinted with material containing at least one active ingredient and constitute the pieces (2^') of the layer comprising at least on active ingredient and wherein each of the different rows (19e), (19f), (19g), (19h) (19i) contains material with an active ingredient that is different from the others. In an example (19e) contains atenolol, (19f) contains pravastatin, (19g) contains ramipril, (19h) contains acetylsalicylic acid (ASA), (19i) contains hydrochlorothiazide. Various active ingredients can be present in the layer containing at least one active ingredient that is divided in a multitude of pieces (2^'). Gap between the cavities / pieces can be from about 50 μηι to about 1 mm (19a, 19d). Side length of the drug cavity or printed layer can be 50 μηι up to 5 mm (19b, 19c).

FIG. 20 shows different options for shape of the cavities (1 ^"") engraved or imprinted in the support material (1 ^"') that can be filled with material containing at least one active ingredient, i.e. square (20a), rectangle (20b), oval (20c), cross (20d), triangle (20e), hexagon (20f), pentagon (20g), disk (20h).

FIG. 21 shows a sectional view of a solid pharmaceutical administration form that is sequentially formed by using the process of the present invention and the composite layer disclosed in FIG. 19.

FIG. 22 and 23 show cross sectional views of a solid pharmaceutical administration form that can be prepared using the process of the present invention and the composite layer shown in FIG. 18 B. The pieces of material comprising at least one active ingredient (2^') that are present in one layer are in an offset position relative to the pieces of material containing at least one active ingredient (2^') that are present in a layer on top of such layer.

FIG. 22 shows a solid pharmaceutical administration form, wherein each piece of material comprising at least one active ingredient (2^') that is present in a layer is arranged adjacent to one another thereby forming a closed structure of the solid pharmaceutical administration form.

FIG. 23 shows a solid pharmaceutical administration form, wherein each piece of material comprising at least one active ingredient (2^') that is present in a layer is arranged apart to one another thereby forming an open structure of the solid pharmaceutical administration form. Compared to the high density arrangement shown in FIG. 22 that provides a limited dissolution rate of active ingredient (2) the low density arrangement shown in FIG. 23 provides an enhanced dissolution rate of active ingredient (2).

FIG. 24 shows a composite layer as in FIG. 4, wherein the support layer (1 ^"') is engraved and includes cavities filled with material comprising at least one active ingredient that constitute the pieces (2^') of the layer comprising at least on active ingredient. The cavities are filled, for example, with compressed active ingredient, viscous- or even liquid active ingredient (option for closed cavities due to additional film layer).

FIG. 25 shows a composite layer as in FIG. 5, wherein the energy absorbing layer (1 ) has engraved cavities that are filled with material comprising at least one active ingredient that constitute the pieces (2^') of the layer comprising at least on active ingredient.

FIG. 26 shows a composite layer as in FIG. 6, wherein the support layer (1 ^"') and the separation layer (13) have engraved cavities that are filled with material comprising at least one active ingredient that constitute the pieces (2^') of the layer comprising at least on active ingredient. FIG. 27 shows a composite layer as in FIG. 7, wherein the laser energy absorbing layer (1 ) and the separation layer (13) have engraved cavities that are filled with material comprising at least one active ingredient that constitute the pieces (2^') of the layer comprising at least on active ingredient.

FIG. 28 shows a composite layer as in FIG. 26, wherein an adhesion layer (14) is attached on the bottom side of the active ingredient containing layer that is divided into pieces (2^').

FIG. 29 shows a composite layer as in FIG. 27, wherein an adhesion layer (14) is attached on the bottom side of the active ingredient containing layer that is divided into pieces (2^').

FIG. 30 shows a solid pharmaceutical administration form which is arranged as core-shell system, wherein the core is made of a multitude of pieces that contain an active ingredient (2^'), which is surrounded by a shell that is made of a multitude of pieces that does not contain an active ingredient (2^"). Core and shell are arranged adjacent to one another thereby forming a closed structure of a solid pharmaceutical administration form.

FIG. 31 shows a solid pharmaceutical administration form as in FIG. 30, wherein a RFID tag (2^"') is placed in the shell made of a multitude of pieces that does not contain an active ingredient (2^"). Due to the geometrical arrangement, upon intake of the solid pharmaceutical administration form, the RFID tag (2^"') is released at first together with the dissolution of the shell which is followed by dissolution and release of active ingredient (2^')

FIG. 32 shows a solid pharmaceutical administration form as in FIG. 30, wherein a RFID tag (2^"') is placed in the core made of a multitude of pieces that contain an active ingredient (2^'). Due to the geometrical arrangement, upon intake of the solid pharmaceutical administration form, exposure and release of the RFID tag (2^"') and active ingredient (2^') to gastrointestinal fluid is delayed as the shell surrounding the core is disintegrated and/or dissolved at first.

FIG. 33 shows a solid pharmaceutical administration form as in FIG. 30 that contains 3 RFID tags (2^"') placed in the shell made of a multitude of pieces that does not contain an active ingredient (2^"), in the outer surface and in the middle of the core made of a multitude of pieces that contain an active ingredient (2^'). By integration of more than one RFID tags the investigation (tracking) period is increased and so that the behavior of the solid pharmaceutical administration form can be monitored from the beginning of the dissolution until its final disintegration and/ or dissolution.

FIG. 34 shows a composite layer wherein a separation layer (13) is present between the laser energy absorbing layer (1 ) and the active ingredient containing layer that is divided into square shaped pieces (2^') having a pinhole (15) in the center, wherein an adhesion layer (14) is attached on the bottom side of said active ingredient containing layer.

FIG. 35 shows the top view of a composite layer as in FIG. 34, which shows the same composite layer as cross-sectional view.

FIG. 36 shows an preferred configuration that can be used for the process of the present invention, wherein with a composite layer (3) is provided as a tape (3^') and transported by roll to roll dispensing system

(1 1 ), (1 1 ^') in a cassette box (1 6). The cassette system is changeable. Positioner rolls (4^'), (4^") is moveable in vertical direction thereby allowing pressing / depressing of the composite layer (3) onto the mounting plate (6) depending from its status of operations. The mounting plate (6) is movable in z-direction and sheeted by a protection tape (10). The laser (5) is activating the print step of the active ingredient onto the mounting plate (6). During assembling the solid pharmaceutical administration form is fixed is fixed by a vacuum chuck (9).

FIG. 37 shows the same configuration as shown in in FIG. 35 as a three- dimensional view. The present invention, without being limited thereby, is further illustrated the following examples.

Example 1 (Production of a layer containing laser energy absorbing material (1 ) or (1 ^"))

195 g of Butylacetate

1 6 g of PVB (polyvinylbutyral, Pioloform,Wacker)

1 1 g Vestosint 2070

3g Aerosil 200

30 g of Sn(Sb)0~(d5o value<1 ,1 μπι) (Du Pont)

Polyvinylbutyral is dissolved in the initially introduced solvent

Butylacetate and stirred well. The laser energy absorbing material Sn(Sb)02 is subsequently stirred in, and a homogeneous paste is prepared. The amount of laser energy absorbing material is dependent on the energy absorption and should be set thereto. The paste is applied to a polyester film having a thickness of 5-250 μηπ, preferably 23μηπ, using a 30μηι doctor blade (hand coater) and dried. The hot lamination can be carried out, for example, using a PE (polyethylene)-coated polypropylene film (Waloten film from Piitz) at about 140Ό.

Example 2 (Production of a layer containing laser energy absorbing material (1 ) or (1 ^")) 200 g of Butylacetate

20 g of PVB (polyvinylbutyral, Piolo form, Wacker)

8 g Vestosint 2070

3 g Aerosil 200

25 g of gas black (d50 value&17 nm) (Special Black 6 from Degussa) The processing is carried out as in Working Example 1 . The laser energy absorbing material employed is gas black. The paste is applied to polyester films having a thickness of 5-250 μηι using a 90 μηι hand coater and dried.

A further polyester film or polypropylene film can be applied to the absorber layer by hot lamination (as described in Working Example 1 ). Example 3 (Production of a layer containing laser energy absorbing material (1 ) or (1 ^"))

200 g of ε-Caprolactam

5 g of PVP (polyvinypyrrolidon)

10 g of Natrosol 250 GR

15 g Vestosint 2070

3g Aerosil 200

25 g of Carbon black powder

The processing is carried out as in Example 1 . The paste is applied to polyester films having a thickness of 5-250 μηι using a 90 μηι hand coater or screenprinter with use of stainless-steel screen of 250mesh/inch, 25μηι wire diameter, 25μηι emulsion thickness. And finally dried in a convection oven at 50°C for 1 hour.

A further polyester film or polypropylene film can be applied to the absorber layer by hot lamination (as described in Working Example 1 ).

Example 4 (Production of a layer containing laser energy absorbing material (1 ) or (1 ^"))

200 g of Masterblend 50 (SICPA-AARBERG AG)

10 g of Iriodin Lazerflair 825 (particle size 20μηπ) (Merck KGaA)

100 g of ethyl acetate/ethanol (1 : 1 )

5 g Vestosint 2070

The laser energy absorbing material Iriodin Lazerflair 825 is incorporated into the Masterblend 50 under gentle conditions and printed by gravure printing onto a polyester film having a thickness of 5-250 μηπ, preferably 23 μηι. The desired viscosity can be set using the solvent mixture ethyl acetate/ethanol. The application rate is 0. 5-1 g/cm. Example 5 (Production of a layer containing laser energy absorbing material (1 ) or (1 ^"))

The layer is produced from polyester already containing laser energy absorbing material by addition of 300 g of Sn(Sb)02 having a particle size of <1 μηι (Du Pont) to the polyester masterbatch (10 kg). Films having a layer thickness of 5-200 μηι are subsequently produced. The finished film contains 0. 05-10% by weight of laser energy absorbing material, depending on the layer thickness.

Example 6 (Production of a layer containing laser energy absorbing material (1 ) or (1 ^"))

The layer is produced from polyester already containing laser energy absorbing material by addition of 330 g of Carbon Black having a particle size of <0,5 μηι to the polyester masterbatch (10 kg). Films having a layer thickness of 5-200 μηι are subsequently produced. The finished film contains 0. 05-10% by weight of laser energy absorbing material, depending on the layer thickness.

Example 7 (Preparation of a medium for an active ingredient containing layer (2))

60 g of 1 ,2-Propandiole

15 g of Glycerol

2 g of Corticosteroid

45 g of Lactose

6 g of Povidone K90

1 1 g of Carboxymethylcellulose

7 g of Magnesiumstearat

2 g of Siliciumdioxide (Aerosil 200 Pharma) The substances are added successive into the liquid mixture of 1 ,2- Propandiol and Glycerol and stirred well, and a homogeneous paste is prepared. The pasty mixture is homogenized by a tree roll mill. The paste is applied to polyester films having a thickness of 5-250 pm using a 90 pm hand coater and dried in a convection oven at 10mbar (inside pressure of the drying chamber) for 1 hour.

Example 8 (Preparation of a medium for an active ingredient containing layer (2))

60 g of 1 ,2-Propandiole

15 g of Glycerol

5 g of a Corticosteroid

40 g of Lactose

10 g of Povidone K90

4 g of Carboxymethylcellulose

3 g of Magnesiumstearat

0,3 g of Siliciumdioxide (Aerosil 200 Pharma)

The substances are added successive into the liquid mixture of 1 ,2- Propandiol and Glycerol and stirred well, and a homogeneous paste is prepared. The pasty mixture is homogenized by a tree roll mill. The paste is applied to polyester films having a thickness of 5-250 pm using a 90 pm hand coater and dried in a convection oven at 10mbar (inside pressure of the drying chamber) for 1 hour.

Example 9 (Preparation of a medium for an active ingredient containing layer (2))

60 g of 1 ,2-Propandiole

15 g of Glycerol

12 g of a Corticosteroid

34 g of Lactose 4 g of Povidone K90

13 g of Carboxymethylcellulose

0,7g of Magnesiumstearat

0,5 g of Siliciumdioxide (Aerosil 200 Pharma) The substances are added successive into the liquid mixture of 1 ,2-

Propandiol and Glycerol and stirred well, and a homogeneous paste is prepared. The pasty mixture are homogenized by a tree roll mill. The paste is applied to polyester films having a thickness of 5-250 pm using a 90 pm hand coater and dried in a convection oven at 10mbar (inside pressure of the drying chamber) for 1 hour.

Example 10 (Preparation of a medium for an active ingredient containing layer (2))

60 g of 1 ,2-Propandiole

65 g of Witepsol H37

12 g of a Corticosteroid

34 g of Lactose

1 g of Povidone K90

13 g of Carboxymethylcellulose

0,7 g of Magnesiumstearat

0,5 g of Siliciumdioxide (Aerosil 200 Pharma)

The substances are added successive into the liquid mixture of 1 ,2- Propandiol and stirred well with high speed dissolver, and a homogeneous paste is prepared. The pasty mixture is homogenized by a tree roll mill. The paste is applied to polyester films having a thickness of 5-250 pm using a 90 pm hand coater and dried in a convection oven at 10mbar (inside pressure of the drying chamber) for 1 hour.

Example 11 (Preparation of a medium for an active ingredient containing layer (2)) 60 g of 1 ,2-Propandiole

10 g PEG 400

65 g of Witepsol W31

12 g of Corticosteroid

34 g of Lactose

1 g of Povidone K90

13g of Carboxymethylcellulose

0,7g of Magnesiumstearat

0,5 g of Siliciumdioxide (Aerosil 200 Pharma)

Example 12 (Preparation of a medium for an active ingredient containing layer (2))

60g of 1 ,2-Propandiole

5g PEG 400

65g of Witepsol S55

12g of a Corticosteroid

34g of Lactose

1 g of Povidone K90

13g of Carboxymethylcellulose

0,7g of Magnesiumstearat

0,5 g of Siliciumdioxide (Aerosil 200 Pharma)

Example 13 (Preparation of a medium for an active ingredient containing layer (2))

60g of 1 ,2-Propandiole

5g PEG 400

65g of Witepsol E85

12g of a Corticosteroid

34g of Lactose

1 g of Povidone K90

13g of Carboxymethylcellulose

0,7g of Magnesiumstearat

0,5 g of Siliciumdioxide (Aerosil 200 Pharma)

Example 14 (Preparation of medium for the separation layer (13))

125 g of 1 ,2-Propandiole

1 g PEG 400

15 g Carnauba wax

5 g of Witepsol E85

34 g of Lactose

1 g of Povidone K90

13 g of Carboxymethylcellulose 0,7 g of Magnesiumstearat

0,5 g of Siliciumdioxide (Aerosil 200 Pharma)

Example 15 (Preparation of medium for the separation layer (13))

125 g of 1 ,2-Propandiole

1 g PEG 400

15 g Carnauba wax

34 g of Lactose

1 g of Povidone K90

13 g of Carboxymethylcellulose

0,7 g of Magnesiumstearat

0,5 g of Siliciumdioxide (Aerosil 200 Pharma)

The substances are added successive into the liquid mixture of 1 ,2- Propandiol and stirred well with high speed dissolver, and a homogeneous paste is prepared. The pasty mixture is finally homogenized by a tree roll mill. The paste is applied to polyester films having a thickness of 5-250 pm using a 90 pm hand coater and dried in a convection oven at 10mbar (inside pressure of the drying chamber) for 1 hour.

Example 16 (Preparation of medium for the separation layer (13))

125g of 1 ,2-Propandiole

1 g PEG 400

20 g Carnauba wax 5 g of Witepsol H37

34 g of Lactose

1 g of Povidone K90

13 g of Carboxymethylcellulose

0,7g of Magnesiumstearat

0,5 g of Siliciumdioxide (Aerosil 200 Pharma)

Example 17 (Preparation of medium for the separation layer (13))

125 g of 1 ,2-Propandiole

1 g PEG 400

25 g Carnauba wax

10 g of Witepsol W31

34 g of Lactose

1 g of Povidone K90

13 g of Carboxymethylcellulose

0,7 g of Magnesiumstearat

0,5 g of Siliciumdioxide (Aerosil 200 Pharma)

The substances are added successive into the liquid mixture of 1 ,2- Propandiol and stirred well with high speed dissolver, and a homogeneous paste is prepared. The pasty mixture is homogenized by a tree roll mill. The paste is applied to polyester films having a thickness of 5-250 pm using a 90 pm hand coater and dried in a convection oven at 10mbar (inside pressure of the drying chamber) for 1 hour. Example 18 (Preparation of medium for the separation layer (13))

150 g of 1 ,2-Propandiole

1 g PEG 400

15 g Carnauba wax

5 g of Witepsol E85

34 g of Lactose

5 g of Povidone K90

13 g of Carboxymethylcellulose

0,7 g of Magnesiumstearat

0,5 g of Siliciumdioxide (Aerosil 200 Pharma)

Example 19 (Preparation of medium for the adhesion layer (14))

150g of 1 ,2-Propandiole

1 g PEG 400

15 g Carnauba wax

34 g of Lactose

6 g of Povidone K90

13 g of Carboxymethylcellulose

0,7 g of Magnesiumstearat

0,5 g of Siliciumdioxide (Aerosil 200 Pharma)

Example 20 (Preparation of medium for the adhesion layer (14))

150 g of 1 ,2-Propandiole

1 g PEG 400

20 g Carnauba wax

5 g of Witepsol H37

34 g of Lactose

7 g of Povidone K90

13 g of Carboxymethylcellulose

0,7 g of Magnesiumstearat

0,5 g of Siliciumdioxide (Aerosil 200 Pharma)

Example 21 (Preparation of medium for the adhesion layer (14))

150 g of 1 ,2-Propandiole

1 g PEG 400

25 g Carnauba wax

10 g of Witepsol W31

34 g of Lactose

7 g of Povidone K90

13 g of Carboxymethylcellulose

0,7 g of Magnesiumstearat

0,5 g of Siliciumdioxide (Aerosil 200 Pharma) The substances are added successive into the liquid mixture of 1 ,2- Propandiol and stirred well with high speed dissolver, and a homogeneous paste is prepared. The pasty mixture is homogenized by a tree roll mill. The paste is applied to polyester films having a thickness of 5-250 pm using a 90 pm hand coater and dried in a convection oven at 10mbar (inside pressure of the drying chamber) for 1 hour.

Example 22 (Production of a composite layer (3) (Figure 4))

The support film (1 ^') and laser energy absorbing layer (1 ^") (Examples 1 - 6) is placed together with the support film (1 ^"') and laminated together with the aid of a hot laminator. The heatable roll is set here to a temperature of 140-175°C. After the hot lamination, the two films are strongly bonded to one another. If a PE-coated polypropylene film (Waloten film from Putz) is used, the lamination can be carried out at about 140Ό. Finally the active ingredient containing layer (2) is applied (Examples 7-13) to the underneath side of the laminated support film (1 ^"').

Example 23 (Production of a composite layer (3) (Figure 6))

The support film (1 ^') and laser energy absorbing layer (1 ^") (Examples 1 - 6) is placed together with the support film (1 ^"') and laminated together with the aid of a hot laminator. The heatable roll is set here to a temperature of 140-175°C. After the hot lamination, the two films are strongly bonded to one another. If a PE-coated polypropylene film (Waloten film from Putz) is used, the lamination can be carried out at about 140Ό. The separation layer (13) is applied (Examples 14-17) to the underneath side of the laminated support film (1 ^"'). The active ingredient containing layer (2) (Examples 7-13) is applied to the separation layer. Finally the adhesion layer (14) is applied (Examples 18-21 ) to the active ingredient containing layer (2). Example 24 (Production of a composite layer (3) (Figure 5))

The medium for the active ingredient containing layer (2) (Examples 7- 13) is applied to the laser energy absorbing layer (1 ) in a layer thickness of 225 μηι (Examples 5-6) and dried.

Example 25 (Production of a composite layer (3) (Figure 14))

The medium for the active ingredient containing layer (2) (Examples 7- 13) is applied to the underneath side of a PET film (thickness: 5,12, 15, 19, 23, 36, 50 and 200 μιτι) in a layer thickness of 10 μηι up to 500 μηπ, and a laser energy absorbing layer (Examples 1 -6) is printed onto the laser side (upper side) in a layer thickness of 0,7-15 μηι.

Example 26 (Preparation of medium for the separation layer (13))

15g of Water

5 g of Ethanol

10g of Povidone

6g of Polyethylenglycol 6000

6g of Kolliphor P188

0,2 g of Magnesiumstearat

0,1 g of Siliciumdioxide (Aerosil 200 Pharma)

The substances are added successive into the liquid mixture of

Water/Ethanol and stirred well with high speed dissolver, and a

homogeneous paste is prepared. The paste is applied to polyester films having a thickness of 5-100 micron using a 30 micron hand coater and dried in a convection oven at 50°C, 10mbar (inside pressure of the drying chamber) for 5minutes.

Example 27 (Preparation of a medium for an active ingredient containing layer (2)) 45g of Water

15 g of Ethanol

9g of Povidone

12g of Sorbitol

24g of Ibuprofen

9 g of Magnesiumstearat

0,1 g of Siliciumdioxide (Aerosil 200 Pharma)

The substances are added successive into the liquid mixture of

Water/Ethanol and stirred well with high speed dissolver, and a

homogeneous paste is prepared. The paste is applied to polyester films having a thickness of 5-150 micron using a 200 micron hand coater and dried in a convection oven at 50°C, 10mbar (inside pressure of the drying chamber) for 10 minutes.

Example 28 (Detailed description of the operation of a preferred embodiment of an apparatus usable for the process of the present invention (Figure 36))

Step 1

A cassette system is implemented into the 3D printer device which includes a tape (3^') of the composite layer (3), which is shown in FIG. 7.

Step 2

A protection tape (10) is placed onto the mounting plate (6). Step 3

The mounting plate (6) is adjusted on zero level for the start position. Step 4

The composite layer (3) is forwarded by the step engine to the start position.

Step 5 Positioner roll (4^') and (4^") drops down to press the composite layer (3) onto the mounting plate (6).

Step 6

The tension of the composite layer between the two rolls (1 1 ) and (1 1 ^') is adjusted to an appropriate tension and the vacuum pump (9) is switched on.

Step 7

The laser scans a defined area thereby transferring the active ingredient containing layer (2) onto the mounting plate (6). Step 8

The positioner rolls (4^') and (4^") are moved up for complete liftoff of the active ingredient layer (2).

Step 9

The composite layer (3) (provided as tape (3^')) is scrolled forward by the stepper motor thereby positioning new (intact) composite layer (3) to the scanning area.

Step 10

The mounting plate (6) is moved down with a height that is identical to the thickness of the active ingredient layer (2). Step 1 1

Positioner roll (4^') and (4^") drops down to press the composite layer (3) onto the mounting plate (6).

Step 12

Repeating the process steps 6 to 1 1 as often as needed to build up the solid pharmaceutical administration form;

Step 13 Switch off the vacuum pump (9) and removal of the solid pharmaceutical administration form from the mounting plate (6).

Example 29 (Production of a solid pharmaceutical administration form in accordance to example 28)

Starting with production of a composite layer (3) (Figure 7)) Step 1

Preparation of the medium for separation layer (13)

15g of Water

5 g of Ethanol

10g of Povidone

6g of Polyethylenglycol 6000

6g of Kolliphor P188

0.1 g of Siliciumdioxide (Aerosil 200 Pharma)

The substances are added successive into the liquid mixture of

Water/Ethanol and stirred well with high speed dissolver, and a

homogeneous paste is prepared. The paste is applied to polyester films having a thickness of 50 micron using a 30 micron hand coater and dried in a convection oven at 50°C, 1013mbar for 5minutes.

Step 2

Preparation of a medium for an active ingredient containing layer (2))

45g of Water

15 g of Ethanol

9g of Povidone

12g of Sorbitol

24g of Ibuprofen

9 g of Magnesiumstearat

0,1 g of Siliciumdioxide (Aerosil 200 Pharma) The substances are added successive into the liquid mixture of

Water/Ethanol and stirred well with high speed dissolver, and a

homogeneous paste is prepared. The paste for the active ingredient containing layer (2) is applied to the separation layer having a thickness of 70 micron using a 200 micron hand coater and dried in a convection oven at 50Ό, 1013 mbar for 10 minutes.

Step 3

Cutting of the composite layer (3) in stripes of 2 cm width thereby obtaining tapes (3^') that are rolled on a core roll (1 1 ).

Step 4

Assembling the core roll (1 1 ) in a cassette system (1 6) and connecting it with the recoil roll (1 1 ^').

Step 5

Implementation of the cassette system (16) to the configuration shown in FIG. 36

Further Steps

Conducting Steps 2 to 13 set forth in Example 28. As a result a solid pharmaceutical administration form having total weight of 400mg containing 39% (w/w) Ibuprofen is obtained.

Experimental conditions

Composite layer (1 ) with a separation layer (13), active ingredient containing layer (2) and adhesion layer (14) (FIGS. 4-17 and 24-29) are employed for the method of the present invention with the aid of the following laser types and parameters:

a) Nd:YAG (cw mode)

12 watt laser Trumpf laser

Nd: YAG (1064 and 532 nm)

Laser intensity: 10— 100%, cw mode

Speed: 100— 5000 mm/s

Line width: 0,1 mm

Line gap: 0,05mm

b) Nd:YVOa laser (cw mode, pulsed)

1 6 watt laser Rofin Sinar

Nd: YVO4 (1064 nm)

Laser intensity: 20— 90%, cw mode, pulsed

Pulse frequency: 10— 100 kHz

Speed: 400—2000 mm/s

c) Nd: YAG laser (pulsed)

60 watt laser Baasel

Nd: YAG (1064

Nd:YAG (pulse mode) 12 watt laser Trumpf laser

Nd:YAG (1064nm)

Laser intensity: 10— 100%, pulse mode

Speed: 100— 5000 mm/s

Pulse frequence: 5kHz

Line width: 0,1 mm

Line gap: 0,05mm

Lamp current 1 6 A, pulsed mode Pulse frequency: 20.000 Hz

Speed: 200 mm/s

Wobbler frequency: 1 6 Hz

Pulse duration: 0.05 ms

Compared with the printing in cw mode of small structures (linewidth

<1 mm or dot diameter <1 mm), the final 3D printing result in pulsed mode are distinguished by greater edge sharpness and smoother surface at the laser printing points.

Claims

Patent Claims ) A process for the manufacture of a solid pharmaceutical administration form comprising at least one active ingredient comprising the steps

(a) positioning a composite layer (3) comprising a laser energy

absorbing layer (1 ) and a layer that contains at least one active ingredient (2) between a plate (4) that is permeable for a laser beam that can be activated by a source of laser energy (5) and a mounting plate (6) whereat the layer of the composite containing at least one active ingredient (2) is positioned opposite to the source of laser energy (5) and is facing to the mounting plate (6);

(e) removing the solid pharmaceutical administration form from the

mounting plate.

2) A process for the manufacture of a solid pharmaceutical administration form comprising at least one active ingredient comprising the steps

(a) positioning a composite layer (3) comprising a laser energy

absorbing layer (1 ) and a layer that contains at least one active ingredient (2) between between a plate (4) that is permeable for a laser beam that can be activated by a source of laser energy (5) and a mounting plate (6) comprising at least one area (7) that is movable in vertical direction (z axis) relative to the mounting plate whereat the layer of the composite containing at least one active ingredient (2) is positioned opposite to the source of laser energy (5) and is facing to the mounting plate (6);

(e) removing the solid pharmaceutical administration form from the

mounting plate.

3) Process according to Claim 1 or 2, characterized in that a vacuum is

applied via a vacuum chuck (9) to hold the solid pharmaceutical administration form on the mounting plate (6) or its movable area (7) during its assembling.

4) Process according to one or more of Claims 1 to 3, characterized in that the composite layer (3) is provided as a tape (3^') and that the positioning of the composite layer (3) in step (a) is achieved by roll (1 1 ) to roll (1 1 ^') transport.

5) Process according to one or more of Claims 1 , 3 and 4, characterized in that the mounting plate is covered by a protection tape (10) and that such protection tape (10) is moved after completion of the pharmaceutical administration form along the mounting plate (6) (x-axis) to provide an empty place for assembling a new solid pharmaceutical administration form.

6) Process according to Claim 5, characterized in that the protection tape (10) is moved by roll (12) to roll (12^') transport.

7) Composite layer usable for the process according to one or more of Claims 1 to 6 comprising a laser energy absorbing layer (1 ) and a layer that contains at least one active ingredient (2).

8) Composite layer according to Claim 7, characterized in that the laser

energy absorbing layer (1 ) comprises a layer comprising a laser energy absorbing material (1 ^") that is covered on one or both sides with support layers (1 ^'), (1 ^"') of a plastic material.

9) Composite layer according to Claim 7, characterized in that the energy absorbing layer (1 ) consists of one layer, wherein a laser energy absorbing material is distributed within a plastic material.

10) Composite layer according to one or more of Claims 7 to 9, characterized in that the plastic material is selected from the group of polymers from the group of polyethylene (PE), polypropylene (PP), polyvinylchloride (PVC), polystyrol (PS), polytetrafluorethylene (PTFE), poly(methyl methacrylate) (PMMA), polyacrylnitril (PAN), polyacrylamid (PAA), polyamide (PA), aramide (polyaramide), (PPTA, Kevlar®, Twaron®), poly(m-phenylen terephthalamid) (PMPI, Nomex®, Teijinconex®), polyketons like

polyetherketon (PEK), polyethylene terephthalate (PET, PETE), polycarbonate (PC), polyethylenglycol (PEG), polyurethane (PU), Kapton K and Kapton HN is poly (4,4'-oxydiphenylene-pyromellitimide),

Poly(organo)siloxane, Melamine-resin (MF).

1 1 ) Composite layer according to one or more of Claims 7 to 10, characterized in that the laser energy absorbing material is indium oxide, indium tin oxide

(ITO), antimon tin oxide (ATO), antimon oxide, tin oxide, zinc oxide, aluminium zinc oxide (AZO), a mixture of metal oxides, zinc sulfide, tin sulfide, carbon black, graphite, metal oxides, silicates, metal oxide coated mica or S1O2 flakes, a conductive pigment, sulfides, phosphates, BiOCI, anthracene, perylenes, rylenes, pentaerythritol or a mixture of two or more materials thereof.

12) Composite layer according to one or more of Claims 7 to 1 1 , characterized in that the laser energy absorbing layer (1 ) contains copolymers of ethylene/ethylene acrylate, epoxy resins, polyesters, polyisobutylene, polyamides, polystyrene, acrylic polymers, polyamides, polyimides, melamine, urethane, benzoguanine and phenolic resins, silicone resins, micronized cellulose, fluorinated polymers (PTFE, PVDF inter alia) and micronized wax as filler or mixtures thereof. 13)Composite layer according to one or more of Claims 7 to 12, characterized in that it comprises a separation layer (13), which is located between the energy absorbing layer (1 ) and the layer that contains at least one active ingredient (2).

14)Composite layer according to Claims 13, characterized in that the

separation layer (13) comprises at least a saccharide, which can be a disaccharide such as sucrose or lactose, a polysaccharide such as starch, cellulose or a derivative thereof, a modified cellulose such as a

microcrystalline cellulose or a cellulose ether, such as hydroxy propyl cellulose (HPC), croscarmellose sodium, a sugar alcohol such as xylitol, sorbitol or maltitol, glucose, a protein such as gelatin, a synthetic polymer such as polyvinylpyrrolidone (PVP) or polyethylene glycol (PEG), cross linked polyvinyl N-pyrrolidone, Tragacanth, Gummi Arabicum, a low melting wax such as beeswax, candelilla wax, carnauba wax, ceresine wax, microcrystalline wax, poloxamer, magnesium stearate, ozokerite wax or paraffin wax and combinations thereof.

15) Composite layer according to one or more of Claims 7 to 13, characterized in that it comprises an adhesion layer (14) which is located outward and opposite to the energy absorbing layer (1 ).

1 6) Composite layer according to Claims 13, characterized in that the

adhesion layer (14) comprises methyl cellulose, liquid glucose, tragacanth, ethyl cellulose, gelatin, hydroxy propyl methyl cellulose (HPMC), starch paste, hydroxy propyl cellulose, croscarmellose sodium, pregelanized starch, sodium carboxy methyl cellulose, algenic acid, polyvinyl pyrollidone (PVP), cross linked polyvinyl N-pyrrolidone, cellulose, gummi arabicum, poloxamer, magnesium stearate, polyethylene glycol (PEG) or

combinations thereof.

17) Composite layer according to one or more of Claims 7 to 16, characterized in that it is provided in a recoiled form in a roll dispenser (1 1 ^").

18) Cassette (1 6) usable for the process according to Claims 1 to 6 having a roll (1 1 ) to roll (1 1 ^') transport mechanism wherein such roll (1 1 ) to roll (1 1 ^') transport mechanism is equipped with the composite layer (3).