Integrated optical and thermal modeling for the development of a scalable multi-sample light-assisted drying platform for biologic stabilization.

Introduction: Light-Assisted Drying (LAD) is a new technique for stabilizing biologics such as vaccines and protein-based therapeutics by using near-infrared laser radiation to drive selective water removal and encapsulate materials within a protective sugar matrix. This process enables room-temperature storage of biological products and reduces dependence on costly cold-chain logistics. While previous studies utilized single-sample LAD, this work introduces a multi-sample platform for the first time. By integrating optical and thermal modeling, we demonstrate that 1,064 nm radiation allows for energy reuse across vertically stacked samples to enable scalable, high-throughput processing. Methods: LightTools optical simulations were used to model laser energy deposition across vertically stacked samples. A lumped-parameter thermal model was developed to predict temperature evolution and drying behavior during laser irradiation. Together, these models guided the design of a processing system. A prototype system was subsequently constructed and tested. Results: LightTools simulations revealed that each sample absorbed Discussion: These findings demonstrate the feasibility of a high-throughput LAD system and represent an important step toward its industrial-scale implementation for biologic preservation.