Polymers for Extrusion-Based 3D Printing of Pharmaceuticals: A Holistic Materials-Process Perspective

Area of Science:

• Pharmaceutical Manufacturing
• Materials Science
• Advanced Manufacturing Technologies

Background:

• Traditional pharmaceutical manufacturing adheres to a 'one-size-fits-all' approach.
• Three dimensional (3D) printing allows for the creation of intricate dosage forms with tailored drug release profiles.
• Polymers are essential materials for pharmaceutical 3D printing applications.

Purpose of the Study:

• To provide a comprehensive materials-process perspective on polymers for extrusion-based 3D printing in pharmaceuticals.
• To focus on fused deposition modeling (FDM) and pressure-assisted microsyringe (PAM) 3D printing techniques.
• To discuss the suitability of polymers and the impact of polymer-active pharmaceutical ingredient (API) combinations on the printing process.

Main Methods:

• Review and synthesis of existing research on extrusion-based 3D printing for pharmaceuticals.
• Analysis of polymer properties and rheology in the context of FDM and PAM processes.
• Discussion of material-characterization techniques for printed pharmaceutical structures.

Main Results:

• Extrusion-based 3D printing, specifically FDM and PAM, shows significant potential for pharmaceutical manufacturing.
• Polymer rheology is a critical factor for successful 3D printing of dosage forms and structures.
• Understanding material-process interactions is key to optimizing 3D printed pharmaceuticals.

Conclusions:

• 3D printing enables personalized medicine and complex drug delivery systems, moving beyond traditional manufacturing limitations.
• Further research into material science, process optimization, and regulatory frameworks is needed for widespread adoption.
• The technology is advancing towards multi-drug printing and personalized pharmaceutical solutions.