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Updated: May 8, 2026
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Micro-masonry for 3D Additive Micromanufacturing
Published on: August 1, 2014
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An Additive Manufacturing MicroFactory: Overcoming Brittle Material Failure and Improving Product Performance through
Elke Prasad1,2, John Robertson1,2, Gavin W Halbert1,2
1EPSRC Future Manufacturing Research Hub in Continuous Manufacturing and Advanced Crystallisation, University of Strathclyde, Technology and Innovation Centre, 99 George Street, Glasgow G1 1RD, UK.
Polymers
|September 28, 2024
Summary
This study introduces a one-step 3D printing process using the MicroFactory to create immediate-release oral solid dosage forms from difficult-to-print materials. This novel method enables consistent drug release profiles for pharmaceutical formulations.
Area of Science:
- Pharmaceutical Sciences
- Materials Science
- Chemical Engineering
Background:
- Traditional 3D printing of oral solid dosage (OSD) forms involves a two-step process, often limited by the properties of pharmaceutical materials.
- Developing suitable formulations for brittle materials requires significant time and complex approaches.
Purpose of the Study:
- To develop a single-step additive manufacturing process for immediate-release OSD forms using a novel filament-free melt extrusion 3D printer.
- To successfully print a previously 'non-printable' brittle formulation containing mefenamic acid (MFA).
- To achieve consistent and targeted drug release profiles.
Main Methods:
- Utilized a novel, filament-free melt extrusion 3D printer (MicroFactory) for a single-step manufacturing process.
- Formulated a mefenamic acid (MFA)-Soluplus®-D-sorbitol mixture for 3D printing.
- Characterized physico-chemical properties using thermal analysis, FTIR, and XRPD.
- Assessed processability via rheology and evaluated OSD performance (mass/content uniformity, dissolution).
Main Results:
- Successfully printed a brittle MFA-Soluplus®-based formulation using the MicroFactory.
- Confirmed the crystalline state of MFA as polymorphic form I.
- 3D printed OSDs exhibited good uniformity and consistent immediate-release dissolution profiles.
- Mathematical modeling correlated dissolution parameters with tablet porosity.
Conclusions:
- The MicroFactory enables a streamlined, one-step additive manufacturing process for OSD forms.
- This technology facilitates the processing of brittle pharmaceutical polymers for immediate-release applications.
- Additive manufacturing improves control over drug dissolution profiles and manufacturing efficiency.
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