Filament-based 3D-printing of placebo dosage forms using brittle lipid-based excipients

Area of Science:

• Pharmaceutical Technology
• Materials Science
• Chemical Engineering

Background:

• Limited availability of polymer excipients for 3D printing pharmaceutical products.
• Lipid-based excipients (LBEs) are underexplored due to processing challenges from their crystalline nature.

Purpose of the Study:

• To evaluate the functionality of LBEs for filament-based 3D printing of oral dosage forms.
• To establish a structure-function relationship for LBEs in extrusion and 3D printing.

Main Methods:

• Selected polyglycerol partial ester of palmitic acid and polyethylene glycols monostearate as LBEs.
• Investigated thermal behavior and supercooling of lipids as critical attributes.
• Compared powder feeding versus a devised liquid feeding setup for filament extrusion.
• Modified a 3D printer for optimal processing of lipid-based filaments.

Main Results:

• Liquid feeding significantly improved filament flexibility and printability compared to powder feeding.
• Polyglycerol ester of palmitic acid yielded filaments with superior performance.
• Understanding lipid thermal behavior and supercooling was crucial for successful processing.
• In-house 3D printer modifications were essential for defect-free printing.

Conclusions:

• LBEs, particularly polyglycerol ester of palmitic acid, can be successfully utilized for 3D printing pharmaceutical dosage forms.
• Liquid feeding strategies and tailored lipid formulations overcome processing challenges associated with LBEs.
• This study expands the excipient options for 3D printing, enabling novel drug delivery systems.