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Novel On-Demand 3-Dimensional (3-D) Printed Tablets Using Fill Density as an Effective Release-Controlling Tool
Rishi Thakkar1, Amit Raviraj Pillai1, Jiaxiang Zhang1
1Pharmaceutical Engineering and 3D Printing (PharmE3D) Labs, Division of Molecular Pharmaceutics and Drug Delivery, College of Pharmacy, The University of Texas at Austin, Austin, TX 78705, USA.
Fill density in 3D printed tablets effectively controls drug release without altering the formulation. Adjusting infill percentage in fused deposition modeling (FDM) allows for personalized medication delivery, with lower densities increasing release speed.
Area of Science:
- Pharmaceutical Sciences
- Materials Science
- Drug Delivery Systems
Background:
- The integration of hot-melt extrusion (HME) and fused deposition modeling (FDM)-based 3-dimensional (3-D) printing has opened avenues for personalized medication.
- Controlling drug release dynamics is crucial for patient-specific dosage forms.
- Fill density presents a novel parameter for modulating drug release from 3D printed matrices.
Purpose of the Study:
- To investigate the impact of fill density on the release of a poorly water-soluble drug from a hydroxypropyl methylcellulose acetate succinate (HPMC-AS) matrix.
- To establish a mathematical and experimental correlation between fill density and drug release performance.
- To assess the feasibility of using fill density as a formulation strategy for 3D printed dosage forms.
Main Methods:
- Development of amorphous solid dispersions (ASDs) of ibuprofen with HPMC-AS using HME.
- Solid-state characterization (DSC, pXRD, PLM) to confirm the amorphous state.
- Fused deposition modeling (FDM) to print 3D tablets with varying fill densities (20-80%).
- In vitro pH shift dissolution studies to evaluate drug release profiles.
Main Results:
- Solid-state characterization confirmed the amorphous state of ibuprofen in HPMC-AS filaments and 3D printed tablets.
- Texture analysis indicated robust mechanical properties of the printed filaments.
- Fill density significantly impacted drug release (p < 0.0001), showing a strong negative correlation (r > -0.99; p < 0.0001).
- 20% infill resulted in the fastest drug release, while 80% infill demonstrated a more controlled release profile.
Conclusions:
- Fill density is a significant and effective parameter for controlling drug release from 3D printed dosage forms.
- This research provides a foundation for developing robust formulation strategies to tailor drug release based on patient needs.
- The study highlights the potential of FDM printing and fill density modulation for personalized pharmaceutical applications.
