Polymeric implants with high drug loading and long-acting drug release and methods of making the same

A controlled release drug delivery system comprising an implantable or administered device that provides controlled release of at least one pharmaceutically active agent throughout an extended drug delivery time period, the implantable device comprising a drug-loaded polymer formed by a process comprising:

• utilizing a phase inversion technique to produce an insoluble solid composition, the phase inversion technique comprising introducing a solution to an aqueous medium, the solution comprising (a) a biodegradable polymer, wherein the biodegradable polymer is poly (lactic-co-glycolic acid (PLGA), (b) a water miscible biocompatible organic solvent, wherein the water miscible biocompatible organic solvent comprises N-methyl-2-pyrrolidone (NMP), (c) at least one pharmaceutically active agent, and optionally (d) a release rate-limiting agent, wherein the ratio of biodegradable polymer to water miscible biocompatible organic solvent in the solution is from 1:2 to 1:6, wherein the solvent diffuses into the aqueous medium during phase inversion to cause the polymer and active agent to precipitate to provide the insoluble solid composition comprising the pharmaceutically active agent and the polymer;
• completely removing residual water miscible biocompatible organic solvent from the insoluble solid composition, thereby providing a dry insoluble composition;
• micronizing the dry insoluble solid composition;
• and
• utilizing direct compression of the micronized dry insoluble solid composition to form a solid tablet forming the implantable or administered device,
• wherein following implantation or administration of the device into a subject, the device results in a serum level of the pharmaceutically active agent sufficient to achieve therapeutic efficacy during the extended drug delivery time period.