A flexible-dose dispenser for immediate and extended release 3D printed tablets

Area of Science:

• Pharmaceutical Technology
• 3D Printing in Medicine
• Personalized Medicine

Background:

• Personalized medicine drives demand for adaptable pharmaceutical manufacturing.
• Existing methods struggle with precise digital dose control and flexibility.
• Need for reliable, fast, and accurate tablet production systems.

Purpose of the Study:

• To develop a flexible tablet system using 3D printing for personalized medicine.
• To integrate Hot Melt Extrusion (HME) with Fused Deposition Modelling (FDM) 3D printing.
• To achieve digitally controlled dosing with high accuracy and release profiles.

Main Methods:

• Developed a pharmaceutical filament using HME compatible with various polymers (Eudragit, HPC SSL).
• Utilized Fused Deposition Modelling (FDM) 3D printing for tablet fabrication.
• Employed computer software for digital dose control and validated with theophylline.

Main Results:

• Achieved dose accuracy between 91-95% through digitally controlled FDM 3D printing.
• Demonstrated compatibility with methacrylic and cellulose-based polymers.
• Confirmed theophylline remained in crystalline form with minimal impact on release and accuracy from higher resolution printing.

Conclusions:

• The HME-FDM 3D printing method offers a viable solution for personalized, digitally controlled tablet production.
• The system supports both immediate and extended release formulations with realistic drug loading.
• The technology shows significant potential for advancing individualized patient treatments.