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Combinatorial 3D printed dosage forms for a two-step and controlled drug release.

Christos S Katsiotis1, Evgenii Tikhomirov1, Maria Strømme1

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European Journal of Pharmaceutical Sciences : Official Journal of the European Federation for Pharmaceutical Sciences
|June 5, 2023
PubMed
Summary

This study combines fused deposition modeling (FDM) and selective laser sintering (SLS) additive manufacturing to create tunable drug delivery devices. The hybrid approach offers controlled theophylline release, overcoming limitations of individual AM methods.

Keywords:
Controlled drug releaseFDMFused deposition modelingHybrid systemSLSSelective laser sintering

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Area of Science:

  • Pharmaceutical Science
  • Materials Science
  • Biomedical Engineering

Background:

  • Fused Deposition Modeling (FDM) and Selective Laser Sintering (SLS) are key additive manufacturing (AM) techniques in pharmaceutical research.
  • Existing AM methods have limitations that necessitate the development of advanced, combinatorial systems for drug delivery.

Purpose of the Study:

  • To develop and evaluate hybrid additive manufacturing systems combining SLS inserts and FDM shells for controlled drug release.
  • To demonstrate the potential of these hybrid systems for tunable drug delivery of theophylline.

Main Methods:

  • Fabrication of hybrid drug delivery devices using SLS for inserts and FDM for a two-compartment shell.
  • Incorporation of theophylline as a model drug into the SLS inserts.
  • Characterization of drug amorphization, dosage, and release kinetics through varying sintering parameters and insert combinations.

Main Results:

  • Selective Laser Sintering (SLS) induced partial amorphization of theophylline, beneficial for poorly soluble drugs.
  • Sintering parameters effectively controlled drug dosage and release kinetics from SLS inserts.
  • Combinations of SLS inserts within the FDM shell enabled diverse drug release profiles, including two-step and prolonged release patterns.

Conclusions:

  • Combining SLS and FDM additive manufacturing offers a modular approach to overcome individual technique limitations.
  • Hybrid AM systems provide a highly tunable platform for developing advanced pharmaceutical drug delivery devices.
  • This proof-of-concept study validates the potential of hybrid AM for precise control over drug release profiles.