Expert opinion on extrusion-based pharmaceutical 3D printing from the European Society of Hospital Pharmaceutical Technology (GERPAC).

Factors affecting 3D printing and post-processing capacity of cookie dough

The widespread use of digital imaging can now be combined with additive three-dimensional (3D) printing, changing traditional clinical dentistry, especially in challenging cases. Visualizing the bone and soft tissue anatomy using computed tomography (CT) and intraoral scanning generated digital files that can be further processed for 3D printing. Among the popular 3D printing approaches, fused filament fabrication (FFF) and stereolithography (SLA) are broadly used due to their rapid production, precision, and ease of use. The current case series outlines three challenging clinical scenarios where a combination of CT and intraoral scans were utilized for digital planning. FFF multicolor anatomical models and SLA surgical guides were produced using 3D printing technology. The first case outlines the utility of this approach to place the optimal surgical window at the lateral sinus lift with anticipated difficult access. In the second case, distinct sites for autogenous bone harvesting were identified while preserving critical adjacent structures with surgical simulation. Finally, the third case outlines this strategy for optimal surgical access to expose an impacted second premolar. Both clinicians and patients benefited from the educational use of FFF‒SLA 3D-printed models, and all cases were successfully treated without complications. These cases demonstrate the significant utility of these digital technologies and rapid prototyping for improved pre-surgical planning, patient motivation, and didactic training that contribute to improved quality of clinical care. To the authors' knowledge, this is the first case reports employing both fused filament fabrication (FFF) and stereolithography (SLA) printing techniques in dental surgery. This innovative approach addresses a range of clinically challenging scenarios presented in this report. Computed tomography (CT) and intraoral scanning are essential for three-dimensional (3D) reconstruction. Specialized software is required to design the guide with precise specifications, and FFF and SLA printers are necessary for fabricating the 3D model. Three-dimensional reconstruction can be time-intensive, particularly when manual segmentation is necessary. Acquiring proficiency in the software may require additional time, and multicolor 3D printing also demands extended printing durations. This study explores how digital imaging and three-dimensional (3D) printing can improve complex dental surgeries. Using tools such as computed tomography scans and intraoral scans, dentists can create detailed 3D models of a patient's bone and soft tissues. Two popular 3D printing methods-fused-filament fabrication (FFF) and stereolithography (SLA)-were used to make these models, which help with surgical planning. The study includes three cases where 3D-printed models were used to prepare for difficult dental procedures. In the first case, the 3D model helped plan the best way to access a difficult area for sinus surgery. The second case used the model to identify the best sites for bone harvesting. The third case used the model to plan how to safely expose an impacted tooth. These helped both the dentist and the patient understand the procedure better. All surgeries were successful, demonstrating how FFF and SLA 3D printing enhance planning, making advanced dental surgeries safer and more efficient.

Three dimensional (3D) printing as an advanced manufacturing technology is progressing to be established in the pharmaceutical industry to overcome the traditional manufacturing regime of 'one size fits for all'. Using 3D printing, it is possible to design and develop complex dosage forms that can be suitable for tuning drug release. Polymers are the key materials that are necessary for 3D printing. Among all 3D printing processes, extrusion-based (both fused deposition modeling (FDM) and pressure-assisted microsyringe (PAM)) 3D printing is well researched for pharmaceutical manufacturing. It is important to understand which polymers are suitable for extrusion-based 3D printing of pharmaceuticals and how their properties, as well as the behavior of polymer–active pharmaceutical ingredient (API) combinations, impact the printing process. Especially, understanding the rheology of the polymer and API–polymer mixtures is necessary for successful 3D printing of dosage forms or printed structures. This review has summarized a holistic materials–process perspective for polymers on extrusion-based 3D printing. The main focus herein will be both FDM and PAM 3D printing processes. It elaborates the discussion on the comparison of 3D printing with the traditional direct compression process, the necessity of rheology, and the characterization techniques required for the printed structure, drug, and excipients. The current technological challenges, regulatory aspects, and the direction toward which the technology is moving, especially for personalized pharmaceuticals and multi-drug printing, are also briefly discussed.

Graphene is an important nanocarbon nanofiller for polymeric matrices. The polymer–graphene nanocomposites, obtained through facile fabrication methods, possess significant electrical–thermal–mechanical and physical properties for technical purposes. To overcome challenges of polymer–graphene nanocomposite processing and high performance, advanced fabrication strategies have been applied to design the next-generation materials–devices. This revolutionary review basically offers a fundamental sketch of graphene, polymer–graphene nanocomposite and three-dimensional (3D) and four-dimensional (4D) printing techniques. The main focus of the article is to portray the impact of 3D and 4D printing techniques in the field of polymer–graphene nanocomposites. Polymeric matrices, such as polyamide, polycaprolactone, polyethylene, poly(lactic acid), etc. with graphene, have been processed using 3D or 4D printing technologies. The 3D and 4D printing employ various cutting-edge processes and offer engineering opportunities to meet the manufacturing demands of the nanomaterials. The 3D printing methods used for graphene nanocomposites include direct ink writing, selective laser sintering, stereolithography, fused deposition modeling and other approaches. Thermally stable poly(lactic acid)–graphene oxide nanocomposites have been processed using a direct ink printing technique. The 3D-printed poly(methyl methacrylate)–graphene have been printed using stereolithography and additive manufacturing techniques. The printed poly(methyl methacrylate)–graphene nanocomposites revealed enhanced morphological, mechanical and biological properties. The polyethylene–graphene nanocomposites processed by fused diffusion modeling have superior thermal conductivity, strength, modulus and radiation- shielding features. The poly(lactic acid)–graphene nanocomposites have been processed using a number of 3D printing approaches, including fused deposition modeling, stereolithography, etc., resulting in unique honeycomb morphology, high surface temperature, surface resistivity, glass transition temperature and linear thermal coefficient. The 4D printing has been applied on acrylonitrile-butadiene-styrene, poly(lactic acid) and thermosetting matrices with graphene nanofiller. Stereolithography-based 4D-printed polymer–graphene nanomaterials have revealed complex shape-changing nanostructures having high resolution. These materials have high temperature stability and high performance for technical applications. Consequently, the 3D- or 4D-printed polymer–graphene nanocomposites revealed technical applications in high temperature relevance, photovoltaics, sensing, energy storage and other technical fields. In short, this paper has reviewed the background of 3D and 4D printing, graphene-based nanocomposite fabrication using 3D–4D printing, development in printing technologies and applications of 3D–4D printing.

Three-dimensional (3D) printing is among the rapidly evolving technologies with applications in many sectors. The pharmaceutical industry is no exception, and the approval of the first 3D-printed tablet (Spiratam®) marked a revolution in the field. Several studies reported the fabrication of different dosage forms using a range of 3D printing techniques. Thermosensitive drugs compose a considerable segment of available medications in the market requiring strict temperature control during processing to ensure their efficacy and safety. Heating involved in some of the 3D printing technologies raises concerns regarding the feasibility of the techniques for printing thermolabile drugs. Studies reported that semi-solid extrusion (SSE) is the commonly used printing technique to fabricate thermosensitive drugs. Digital light processing (DLP), binder jetting (BJ), and stereolithography (SLA) can also be used for the fabrication of thermosensitive drugs as they do not involve heating elements. Nonetheless, degradation of some drugs by light source used in the techniques was reported. Interestingly, fused deposition modelling (FDM) coupled with filling techniques offered protection against thermal degradation. Concepts such as selection of low melting point polymers, adjustment of printing parameters, and coupling of more than one printing technique were exploited in printing thermosensitive drugs. This systematic review presents challenges, 3DP procedures, and future directions of 3D printing of thermo-sensitive formulations.

This review aims to examine the impact of three-dimensional (3D) printing technologies on enhancing psychiatric pharmacotherapy through facilitating personalized and patient-centered drug delivery. This research specifically addresses problems such as poor medication compliance, polypharmacy, and palatability issues, especially in pediatric and elderly populations. A thorough review of the literature was conducted, focusing on novel advances in 3D printing techniques, including fused deposition modeling (FDM), semisolid extrusion (SSE), stereolithography, inkjet printing, binder jetting, and selective laser sintering (SLS). Selected research highlighted the application of such technologies in developing customized oral drug dosage forms. Emphasis was placed on the exploitation of polymers like Eudragit® E PO, flavor-masking excipients, and their combination with biosensor and artificial intelligence (AI) systems. Case studies were assessed to ascertain their relevance and innovation in the development of psychiatric medications. 3D printing allows the manufacture of tailored psychiatric drugs with greater dosing versatility, taste masking, and the ability to merge several active drug ingredients into a single pharmaceutical form. Patient-friendly dosage forms such as chew gummies and chocolate tablets demonstrated enhanced acceptability. Also, forthcoming technologies such as 4D printing and AI-driven biosensors yield intelligent, interactive drug release systems that are specific to individual physiological or behavioral inputs. 3D printing represents a paradigm-shifting advance in psychiatric care, offering solutions to long-standing treatment compliance and fixed-dose challenges. Although regulatory and scalability challenges persist, the intersection of pharmaceutical engineering, material science, and artificial intelligence creates an encouraging platform for the future of precision mental care therapies.

Polylactic acid (PLA) is the most widely used raw material in extrusion-based three-dimensional (3D) printing (fused deposition modeling, FDM approach) in many areas since it is biodegradable and environmentally friendly, however its utilization is limited due to some of its disadvantages such as mechanical weakness, water solubility rate, etc. FDM is a simple and more cost-effective fabrication process compared to other 3D printing techniques. Unfortunately, there are deficiencies of the FDM approach, such as mechanical weakness of the FDM parts compared to the parts produced by the conventional injection and compression molding methods. Preparation of PLA composites with suitable additives is the most useful technique to improve the properties of the 3D-printed PLA parts obtained by the FDM method. In the last decade, newly developed PLA composites find large usage areas both in academic and industrial circles. This review focuses on the chemistry and properties of pure PLA and also the preparation methods of the PLA composites which will be used as a raw material in 3D printers. The main drawbacks of the pure PLA filaments and the necessity for the preparation of PLA composites which will be employed in the FDM-based 3D printing applications is also discussed in the first part. The current methods to obtain PLA composites as raw materials to be used as filaments in the extrusion-based 3D printing are given in the second part. The applications of the novel PLA composites by utilizing the FDM-based 3D printing technology in the fields of biomedical, tissue engineering, human bone repair, antibacterial, bioprinting, electrical conductivity, electromagnetic, sensor, battery, automotive, aviation, four-dimensional (4D) printing, smart textile, environmental, and luminescence applications are presented and critically discussed in the third part of this review.

Tuning the fabrication of knotted reactors via 3D printing techniques and materials

A review of high internal phase Pickering emulsions: Stabilization, rheology, and 3D printing application

The demand for personalized medicine has received extensive attention, especially in pediatric preparations. An emerging technology, extrusion-based 3D printing, is highly attractive in the field of personalized medicine. In this study, we prepared propranolol hydrochloride (PR) gummy chewable tablets tailored for children by semisolid extrusion (SSE) 3D printing technology to meet personalized medicine needs in pediatrics. In this study, the effects of critical formulation variables on the rheological properties and printability of gum materials were investigated by constructing a full-factorial design. In addition, the masticatory properties, thermal stability, and disintegration time of the preparations were evaluated. Bitterness inhibitors were used to mask the bitterness of the preparations. The results of the full-factorial design showed that the amount of gelatin and carrageenan were the key factors in the formulation. Gelatin can improve printability and masticatory properties, carrageenan can improve thermal stability, and accelerate the disintegration of preparations; therefore, a reasonable combination of both could satisfactorily meet the demand for high-quality 3D printing. γ-Aminobutyric acid can reduce the bitterness of gummy chewable tablets to improve medication compliance and the determined formulation (F7) met the quality requirements. In conclusion, the gum material has excellent potential as an extrusion material for 3D printing. The dosage can be adjusted flexibly by the model shape and size. 3D printing has broad prospects in pediatric preparations.

Owing to COVID-19, the world has advanced faster in the era of the Fourth Industrial Revolution, along with the 3D printing technology that has achieved innovation in personalized manufacturing. Three-dimensional printing technology has been utilized across various fields such as environmental fields, medical systems, and military materials. Recently, the 3D food printer global market has shown a high annual growth rate and is a huge industry of approximately one billion dollars. Three-dimensional food printing technology can be applied to various food ranges based on the advantages of designing existing food to suit one’s taste and purpose. Currently, many countries worldwide produce various 3D food printers, developing special foods such as combat food, space food, restaurants, floating food, and elderly food. Many people are unaware of the utilization of the 3D food printing technology industry as it is in its early stages. There are various cases using 3D food printing technology in various parts of the world. Three-dimensional food printing technology is expected to become a new trend in the new normal era after COVID-19. Compared to other 3D printing industries, food 3D printing technology has a relatively small overall 3D printing utilization and industry size because of problems such as insufficient institutionalization and limitation of standardized food materials for 3D food printing. In this review, the current industrial status of 3D food printing technology was investigated with suggestions for the improvement of the food 3D printing market in the new normal era.

This study evaluates the three-dimensional (3D) printing materials used in Fused Deposition Modeling (FDM) printing technology. 3D printing technology has been developing strongly, becoming an effective support tool in production and research. The 3D printing process involves many stages, with many parameters affecting the quality and properties of the product, in which 3D printing material is one of many essential factors affecting that process. The study conducts a comprehensive assessment of the most common materials in 3D printing technology to determine the advantages and limitations of precisely five types of materials: Polylactic acid, acrylonitrile butadiene styrene, polyethylene terephthalate glycol-modified, thermoplastic polyurethane, and acrylonitrile styrene acrylate. With 3D printing, parameters such as sintering temperature, printing speed, and layer thickness are kept constant. These parameters are applied equally to all five material samples. The experiment evaluates the tensile strength of materials. The study results provide an overview of the properties and applicability of 3D printing materials, helping to select materials suitable for specific FDM 3D printing technology applications.

Background and ImportanceIn paediatric hospitals, the lack of age-appropriate licensed medicines for oral use has traditionally been solved by extemporaneous manufacturing of oral liquids, suspensions, dose powders and capsules in...

The purpose of this paper is to make an analysis of the advanced technologies for 3D printing of pharmaceutical products for personalised medicine.A review of the basic 3D printing methods used in pharmaceutical technologies is conducted. The main types of printed solid dosage forms are examined, along with the primary advantages and disadvantages of 3D printing compared to conventional drug production. Each method is evaluated in terms of working principles, material compatibility, advantages, and limitations.Revealed that stereolithography (SLA), selective laser sintering (SLS), fused deposition modelling (FDM), ink-jet printing (IJP), and semi-solid extrusion (SSE) are the most suitable 3D printing processes for producing pharmaceutical products. The combination of two methods ensures better results, as illustrated by examples of the main types of printed solid dosage forms.The 3D printing technologies for production of pharmaceutical products present several limitations such as: uneven geometries and porous structures, necessitating the fabrication of larger and irregular dosage forms to ensure the required drug load for the patient; degradation of thermolabile drugs during FDM process; increased hardness of FDM produced tablets impairing drug release.The advanced 3D printing technologies offer the ability to produce new formulations easily through simple design modifications in software, compared to conventional manufacturing. They enable the design of flexible formulations with complex release profiles and the personalised production of dosage forms tailored to individual patients.3D printing has emerged as a transformative technology in pharmaceutical manufacturing, enabling the production of personalised dosage forms with precise drug loading, tailored release profiles, and complex geometries. The review not only summarises the main applicable techniques but also highlights the most recommended methods for personalised pharmacotherapy. The versatility and adaptability of 3D printing provide promising solutions for personalised therapy, emergency drug manufacturing, and enhanced patient compliance, marking a significant step toward decentralised, digital pharmaceutical production.

There has been a tremendous increase in the investigations of three-dimensional (3D) printing for biomedical and pharmaceutical applications, and drug delivery in particular, ever since the US FDA approved the first 3D printed medicine, SPRITAM® (levetiracetam) in 2015. Three-dimensional printing, also known as additive manufacturing, involves various manufacturing techniques like fused-deposition modeling, 3D inkjet, stereolithography, direct powder extrusion, and selective laser sintering, among other 3D printing techniques, which are based on the digitally controlled layer-by-layer deposition of materials to form various geometries of printlets. In contrast to conventional manufacturing methods, 3D printing technologies provide the unique and important opportunity for the fabrication of personalized dosage forms, which is an important aspect in addressing diverse patient medical needs. There is however the need to speed up the use of 3D printing in the biopharmaceutical industry and clinical settings, and this can be made possible through the integration of modern technologies like artificial intelligence, machine learning, and Internet of Things, into additive manufacturing. This will lead to less human involvement and expertise, independent, streamlined, and intelligent production of personalized medicines. Four-dimensional (4D) printing is another important additive manufacturing technique similar to 3D printing, but adds a 4th dimension defined as time, to the printing. This paper aims to give a detailed review of the applications and principles of operation of various 3D printing technologies in drug delivery, and the materials used in 3D printing, and highlight the challenges and opportunities of additive manufacturing, while introducing the concept of 4D printing and its pharmaceutical applications.