In this work a soaking method for incorporating glibenclamide (GBC), a poorly soluble API, into prefabricated polylactic acid (PLA) filaments intended for 3D printing by fused deposition modeling (FDM) was developed and evaluated. The swelling effect of multiple solvents and solvent mixtures on PLA was assessed to identify an optimal soaking solution. Water and l-arginine (ARG) were selected to modify the soaking method to enhance drug incorporation with minimal filament degradation. The presence of ARG enhanced GBC's solubility in the selected soaking solution and it was associated with a significant increase in the filaments' drug loading. Thermal and infrared spectroscopy studies revealed the absence of a glass transition (Tg) in the soaked filaments and a significant reduction in the melting temperature combined with an increase in the melting enthalpy indicating increased PLA crystallinity. In vitro dissolution studies with filaments and printed tablets indicated that GBC had been well dispersed into the PLA matrix during printing leading to a decrease in drug release. Instead, filaments soaked in GBC-ARG solutions demonstrated increased drug release compared with GBC on its own. Overall, our results show a simple method to improve drug incorporation of a poorly soluble API into PLA filaments via passive diffusion.
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