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Low-temperature FDM 3D printing of immediate-release glipizide tablets: formulation optimization, solid-state
Kasitpong Thanawuth1, Supakij Suttiruengwong2, Kampanart Huanbutta1
1College of Pharmacy, Rangsit University, Pathum Thani 12000, Thailand.
International Journal of Pharmaceutics
|August 3, 2026
Summary
This study developed personalized glipizide (GPZ) tablets using low-temperature 3D printing. Tailoring tablet geometry and internal structure shows promise for immediate-release formulations, but dose-dependent performance needs further optimization.
Area of Science:
- Pharmaceutical Technology
- Materials Science
- Drug Delivery
Background:
- Glipizide (GPZ), a Biopharmaceutics Classification System Class II drug, has poor solubility and high melting point, complicating 3D printing.
- Fused Deposition Modeling (FDM) 3D printing requires high temperatures, posing challenges for thermolabile drugs like GPZ.
Purpose of the Study:
- To investigate low-temperature hot-melt extrusion (HME) and FDM 3D printing for personalized immediate-release GPZ tablets.
- To optimize filament formulation and printing parameters for successful fabrication.
- To assess the impact of printing parameters on drug release and dose scalability.
Main Methods:
- Developed GPZ-loaded filaments using vinylpyrrolidone-vinyl acetate copolymer (KVA64), mannitol (MAN), and triethyl citrate (TEC) via low-temperature HME (60°C).
- Fabricated immediate-release GPZ tablets using FDM 3D printing (90°C).
- Utilized a mixed-level factorial design to study the effects of infill pattern, number of shells, and layer thickness on drug release.
- Characterized drug-excipient compatibility and physical state using DSC, PXRD, and TGA.
- Produced dose-adjusted tablets (5-15 mg) by varying tablet thickness.
Main Results:
- Successfully prepared flexible, feedable, and moisture-resistant GPZ-loaded filaments.
- Identified optimal filament composition (12% GPZ, 69% KVA64, 10% MAN, 9% TEC).
- Found infill pattern and number of shells significantly affected GPZ release; layer thickness effect was dependent on infill architecture.
- Demonstrated that thinner tablets generally released GPZ faster due to increased surface area-to-volume ratio.
- Observed that height-based scaling alone was insufficient for maintaining immediate-release performance for the 15 mg tablet.
Conclusions:
- Low-temperature HME-FDM 3D printing is a viable approach for fabricating personalized immediate-release glipizide tablets.
- Optimizing tablet geometry (thickness) and internal structure (infill, shells) is crucial for controlling drug release.
- Further research is needed to ensure dose scalability and consistent immediate-release performance across a range of dosages.
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