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Drug Dissolution Enhancement Using 3D-Printed Silica-Based Oral Films.

Dagmar Blaháčková1, Jan Elbl1, Lukas C Lammerding2

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Summary

Developing porous orodispersible films (ODFs) and using 3D printing significantly enhanced the dissolution of poorly soluble dexamethasone, offering a promising approach for improved drug delivery.

Keywords:
Drug crystallizationIndividualized therapyOrodispersible filmPorous filmSilica

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Area of Science:

  • Pharmaceutical Sciences
  • Materials Science
  • Drug Delivery Systems

Background:

  • Orodispersible films (ODFs) offer convenient drug administration but struggle with loading poorly soluble drugs.
  • Limited drug loading capacity hinders the development of ODFs for challenging compounds.
  • Optimizing ODF structure is crucial for enhancing the dissolution of poorly soluble active pharmaceutical ingredients.

Purpose of the Study:

  • To develop and characterize porous ODF matrices suitable for 3D printing medicated inks.
  • To investigate the effect of macroporosity on drug dissolution kinetics for both soluble and insoluble drugs.
  • To enhance the release of poorly soluble dexamethasone using porous ODFs and 3D printing.

Main Methods:

  • Fabrication of porous ODFs using solvent casting with silica- and silicate-based porogens.
  • Loading of caffeine and dexamethasone into ODFs via 3D printing.
  • Comprehensive characterization including micro-CT, BET, SEM, Raman, FTIR, XRD, and dissolution studies.

Main Results:

  • Silica-based porogens enabled tunable macroporosity, supporting high drug loads (3-5x ink volume).
  • 3D printed dexamethasone on porous ODFs showed significantly enhanced dissolution (79.2%) compared to powdered form (29.9%).
  • Readily soluble caffeine exhibited a transient dissolution delay, attributed to particle size and film disintegration.

Conclusions:

  • Integrating porous matrix design with 3D printing effectively enhances the dissolution of poorly soluble drugs like dexamethasone.
  • The developed porous ODFs demonstrate high drug loading capacity and improved drug release profiles.
  • Structural modifications of ODFs are key drivers for enhanced drug dissolution without adverse drug-matrix interactions.