Custom Shaping


Novel dosage forms may require innovative and customized pharmaceutical product shaping. Foster Delivery Science’s inventory of downstream processing equipment is available to manufacture traditional and unique/customized products to meet your drug delivery goals.

Drug Delivery and Implantable Polymer Rods

Monofilament rods/fibers for drug delivery and implantable applications are available with diameters typically ranging from 0.012 to 0.2 inches (0.30 to 5 millimeters) for implants, 3D printer strands (per printer specification), woven structures and more.

Co-Extrusion of multilayered filaments can combine properties of different or same polymers to limit the drug release from a core, enhance the durability of the dosage form, or modulate drug release through a fast-dissolving outer layer and a slower releasing inner layer, as examples.

Magnified image of polymer-based, custom drug delivery tubing cross-section, manufactured in pharmaceutical clean room.

Drug Delivery and Implantable Polymer Pellets & Micro-pellets:

Foster’s extrusion shaping expertise extends to micro-pellets and traditional pellet forms, including cylindrical / strand cut and spherical cuts. These materials can then be used as implants or capsule filling, among other operations. Common micro-pellet sizes range from 0.029 to 0.047 inches (0.5 to 1.2 millimeters). Traditional pellets are typically 0.059 to 0.118 inches (1.5 to 3.0 millimeters), depending on the material and the formulation.

Drug Delivery and Implantable Polymer Films:

Films created via Hot Melt Extrusion do not utilize solvents and can be deployed for delayed/controlled drug release implantable applications such as post-operative therapy wraps, or fast dissolving transdermal, transmucosal and buccal patches. Films are available in a range sizes to fit custom application requirements. Typical extrusion capabilities can produce films having sizes up to 5.25 inches (133.4 millimeters) wide and thicknesses of 0.0012 to 0.0394 inches (0.03 to 1.00 millimeters).

Drug Delivery and Implantable Polymer Tubes:

Implantable and drug delivery tubes can be made from a wide range of biocompatible polymers to meet specific application requirements, often acting as a vessel to carry an API payload or a means to increase drug releasing surface area. Single lumen, monolayer tubes are most common for implants with diameters as small as 0.0098 inches (0.25 millimeters) with wall thicknesses as small as 0.0004 inches (0.01 millimeters). Co-extruded tubes and other configurations can be developed.