Structured engineering of self-emulsifying drug delivery systems (SEDDS) via 3D printing: Comprehensive review

The combination of self-emulsifying drug delivery systems (SEDDS) with three-dimensional printing (3DP) technologies represents an innovative and promising strategy for developing personalised dosage forms. Through precise control over dosage form architecture, controlled drug release kinetics, and individualised therapeutic customisation, 3DP offers distinct and transformative advantages over conventional pharmaceutical formulation approaches. This review focuses on the application of modern 3DP techniques, specifically fused deposition modelling (FDM), semi-solid extrusion (SSE), and drop-on-demand (DoD), in the formulation and production of SEDDS. Each technique is critically evaluated in terms of formulation compatibility, operational mechanisms, and its potential to address the current manufacturing challenges associated with SEDDS. 3DP technologies offer several benefits, including enhanced flexibility in production, the ability to fabricate on demand, and the potential to accommodate complex and personalised therapeutic regimens. However, these methods also face notable limitations, such as material constraints, variability in print quality, mechanical and safety issues, and a lack of clear regulatory guidance. Despite their potential, the use of 3DP in SEDDS development remains relatively unexplored. This review aims to provide a comprehensive overview of the current research landscape, identify existing technological and regulatory barriers, and discuss future prospects for integrating 3DP into next-generation SEDDS formulations.