Devices, compositions, and methods for fabricating drug delivery systems

A biologically active agent delivery composition, the composition comprising:

• a polymeric mixture;
• and
• a biologically active agent,
• wherein the biologically active agent delivery composition is a granular material having an average particle diameter less than or equal to about 100 μm, and
• wherein the biologically active agent delivery composition is fabricated by a solid-state shearing device operating at least in part at a temperature less than or equal to a liquefication temperature of the polymeric mixture.

A biologically active agent delivery device comprising:

• a biologically active agent delivery composition, comprising:
• a polymeric mixture, and
• a biologically active agent,
• wherein the biologically active agent delivery composition is a granular material having an average particle diameter less than or equal to about 100 μm, and
• wherein the biologically active agent delivery composition is fabricated by a solid-state shearing device operating at least in part at a temperature less than or equal to a liquefication temperature of the polymeric mixture;
• wherein the biologically active agent delivery composition is fabricated into the biologically active agent delivery device configured for administration into a portion of a body.

A method of fabricating a biologically active agent delivery device, the method comprising:

• introducing a polymeric mixture into an extruder;
• introducing a biologically active agent into the extruder;
• solid-state shearing the polymeric mixture and the biologically active agent together in an initial zone of the extruder to yield the biologically active agent delivery composition, wherein the initial zone has a temperature less than or equal to a liquefication temperature of the polymeric mixture;
• dispensing the biologically active agent delivery composition from the extruder;
• and
• fabricating the biologically active agent delivery device from the biologically active agent delivery composition.

A system for fabricating a biologically active agent delivery composition, the system comprising:

• at least one barrel section;
• at least one extrusion screw disposed within the at least one barrel section;
• a plurality of active elements disposed within the at least one barrel section, wherein the active elements are configured to be operated by the at least one extrusion screw;
• at least one feed chute configured to deliver one or more of a polymeric mixture and a biologically active agent into the at least one barrel section;
• and
• a temperature control system,
• wherein the temperature control system is configured to maintain a temperature of one of more of the one or more barrel sections, the one or more extrusion screws, and the one or more active elements less than or equal to a liquefication temperature of the polymeric mixture.