Ink to innovation: Pioneering printing technologies for next-generation drug delivery systems

Inkjet printing has emerged as a revolutionary technology in pharmaceutical manufacturing, offering unprecedented precision in the deposition of active pharmaceutical ingredients (APIs) and excipients. Its ability to accurately dispense nano- to picolitre volumes without direct contact with the substrate enables the development of complex and highly uniform dosage forms. This technology is uniquely positioned to overcome many limitations of conventional manufacturing processes, especially in the development of personalised and controlled-release formulations. In this review, we provide a comprehensive analysis of the principles, mechanisms, and advancements in inkjet printing technology for pharmaceutical applications. The review covers an overview of the fundamentals of inkjet printing, including drop-on-demand systems, thermal and piezoelectric printing modalities, and the critical parameters that govern droplet formation. We then examine its diverse applications, ranging from studying drugs in solid states to the production of novel formulations and personalised dosage forms. In addition, the integration of inkjet printing with advanced analytical tools is discussed, which has improved quality control and enabled high-throughput screening of drug formulations. Challenges related to ink formulation and process reproducibility are also critically evaluated, providing insights into current limitations and potential strategies for overcoming them. Finally, inkjet printing represents a transformative approach in pharmaceutical formulation development, offering scalability, flexibility, and the potential for on-demand manufacturing of patient-specific therapies. As research continues to refine inkjet printing processes and overcome existing technical challenges, this technology is poised to significantly enhance drug delivery performance and accelerate the transition toward personalised medicine. This review underscores the critical role of inkjet printing in redefining pharmaceutical technology and highlights its promising future in advancing next-generation drug delivery systems.