High-throughput eutectic screening and hot-melt extrusion enable rapid development of nifedipine amorphous solid...

The development of eutectic-based amorphous solid dispersions (ASDs) is often constrained by the time and material required to identify suitable drug-coformer combinations. Here, we present a miniaturised high-throughput workflow that integrates picolitre-volume 2D inkjet printing, predictive thermodynamic modelling, and scalable processing to accelerate eutectic formulation design for the model active pharmaceutical ingredient (API) nifedipine. Binary systems were printed as microarrays and screened microscopically, enabling rapid identification of promising eutectic pairs using minimal material. The Schroeder-Van Laar equation was applied to predict eutectic compositions and onset temperatures, which were subsequently validated through scale-up and full phase-diagram construction. Selected formulations were then processed by hot-melt extrusion to generate amorphous solid dispersions. This end-to-end strategy, spanning ultrafast microarray screening to continuous manufacturing, provides a robust and material-efficient platform for eutectic-based ASD development and substantially shortens formulation timelines for poorly soluble APIs such as nifedipine.