Growth morphology is generally used to describe the external geometry or shape of a crystal.
Habit is also used interchangeably.
It is well known that particle shape, size, size distribution and other mechanical properties
affect manufacturing processes and control product quality.
It is thereby critical to predict and control polymorphism, shape, and size of crystalline materials
for drug discovery and development.
Growth morphology of a crystal is decided by growth rates of its faces.
A fast-growing face becomes a minor one or even disappears in the final shape. Conversely,
a major face has a small growth rate. Understanding the role played by solvent-surface in
enhancing or inhibiting crystal growth has been evolved in two general thoughts.
In one theory, it is suggested that solvent-surface interactions result in changes of interfacial
tension, causing so-called surface roughening and variations in growth rate of crystal faces.
Alternatively, it is proposed that solvent molecules act in a similar way to additives,
preferentially adsorbed on specific faces, posing an additional energy barrier for solute molecules
to attach to solid surfaces. No systematic study of solvent-surface interactions at the electronic
level has been reported with regard to crystal growth of organic crystals.
Four widely-used computational methods have been developed for the morphology prediction: (i)
The Bravais Friedel Donnay Harker (BFDH) method is a geometrical approach that analyzes crystal
lattice and symmetry and generates a list of possible growth faces and their relative growth rates,
from which the crystal morphology can be deduced. (ii) The Attachment Energy method calculates the
energy released when a growth slice is added to a growing plane. The growth rate of the face is
proportional to its attachment energy. Faces with the lowest attachment energies are the slowest
growing and, therefore, have the most morphological importance. A Wulff plot is then constructed
from the energy calculation, producing the final morphology. (iii) The Surface Energy method
predicts the morphology based on the total surface energy of a crystal to be minimized.
The theory behind is the argument by J. W. Gibbs that the morphology is determined by the minimum
of the surface free energy for a given volume and temperature. (iv) The Hartman-Perdok method
provides a systematic way to generate stable growth planes of a crystal.
It removes one of the assumptions of the Attachment Energy method, namely, the growth planes
are always ideal and flat. Once the stable growth planes have been identified, the
Attachment Energy method is used to calculate the growth morphology. Energy calculations in
these methods are typically done with empirical models or force fields.
Nevertheless, these methods are incapable of considering external conditions including solvent and additive.
Some theoretical and computational efforts have been made to predict the morphology of crystals
grown in a solvent. One approach relies on empirical parameters or experimental input such as
contact angle or surface energy to estimate growth rates of different faces in a solvent.
Other methods explicitly consider solvent molecules on crystal surface, and utilize empirical
force fields and molecular dynamics to calculate solvent adsorption and its impact on the
attachment energy.
Still, these isolated efforts have not been able to produce sufficient results and collective insights,
allowing the development of a systematic understanding and a general prediction method.
Moreover, using electronic calculations to consider solvent effect and predict growth morphology of organic
crystals has not been seen in the literature.
Effects of additives on growth morphology have been closely examined by Lahav, Leiserowitz and
co-workers. They have demonstrated using “tailor-made” or structurally similar additives
to control crystal morphology and hinder the growth. These additive molecules typically have a
similar framework to the host molecule with one functional moiety altered.
It has been proposed that additive molecules adsorb and replace host molecules on crystal surfaces
due to similar molecular shapes. Depending on the orientation of altered moieties,
growth of host molecules to specific faces may be hindered, leading to a different morphology.
The role played by additive is elucidated based on molecular shape and geometry hindrance
in terms of adsorption site and orientation of altered functional moieties.
Yet, we have shown in our earlier work that appearance of a new face of acetaminophen single
crystals by using a tailor-made additive could not be explained based on the geometry hindrance.
We suspected the surface reconstruction due to unique additive-surface interactions led to the
morphology change.