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3D Printing for Drug Delivery and its Pharmaceutical Applications – Recent


Findings and Challenges

Article in International Journal of Pharmaceutical Sciences and Nanotechnology · April 2022


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International Journal of
Pharmaceutical Sciences and Nanotechnology (IJPSN)

www.ijpsnonline.com

REVIEW ARTICLE

3D Printing for Drug Delivery and its Pharmaceutical


Applications – Recent Findings and Challenges
Neelima Mandloi*| Kuldeep Vinchurkar1 | Dinesh K Mishra2 | Pankaj Dixit3

Indore Institute of Pharmacy, Indore.


ABSTRACT
*Correspondence author: Neelima Mandloi,
Indore Institute of Pharmacy, 3D Printing technology also known as Additive Manufacturing is a rapid prototyping
Phone: 9589031212, process that construct solid product with various geometrics by successive layers of
E-mail: [email protected].
material by the use of Computer-Aided Design (CAD). The introduction of 3DP
How to cite this article: Mandloi N, Vinchurkar K, technology in the pharmaceutical industry has opened new horizons in the research
Mishra DK, Dixit P. 3D Printing for Drug Delivery and
its Pharmaceutical Applications – Recent Findings and and development of printed materials and devices. The main benefit of 3DP lies in
Challenges. International Journal of Pharmaceutical the production of small batches of medicines each with tailored dosages, shape,
Sciences and Nanotechnology. 2022, 15(2):
size, and release characteristics. This paper presents the current status of research
MS ID: 2260 and development in 3DP technology, background and basic procedure involved in
https://doi.org/10.37285/ijpsn.2022.15.2.11 3DP, main components and types of 3DP, different methods and polymers used,
advantages, limitations, and applications of 3D printing technology.
Keywords
Drug delivery, 3D Printing technology, Pharmaceutical additive manufacturing,
Personalized medicine, Computer-aided design, Polymers, Fused deposition
modeling, Stereolithography, Selective laser sintering, Thermal inkjet.

Introduction
customized medicine and dosing receives increasing
attention due to the high chances of undesirable side
effects.
Drug delivery is a type of technique used for efficient Three-dimensional printing is a form of additive
transport of a pharmacologically active component in the manufacturing technology in which a 3D object is created
body as desired to achieve required therapeutic efficacy by laying down successive layers of material by using
and safety. Within the last decade, considerable Computer-Aided Design (CAD) software. Therefore, it is
attention was focused on the development of novel drug also known by other terminologies such as layered
delivery systems and patient-centric drug products. 3D manufacturing, additive manufacturing, computer
printing is considered to be the most revolutionary automated manufacturing, rapid prototyping, or solid

ABBREVIATIONS: 3DP - Three-dimensional printing; ABS - Acrylonitrile butadiene styrene; AM - Additive manufacturing; API
Active pharmaceutical ingredient; CAD - Computer-aided design; EC – Ethylcellulose; FDA - Food and drug administration; FDM Fused
deposition modeling; HME - Hot melt extrusion; HPMC - Hydroxypropyl methylcellulose; PCL – Polycaprolactone;
PEG - Polyethylene glycol; PLA - Polylactic acid; PVA - Polyvinyl alcohol; PLGA - Poly(lactic-co-glycolic acid); PU – Polyurethane; PMMA
- Poly(methyl methacrylate); SLA – Stereolithography; SLS - Selective laser sintering; TIJ - Thermal inkjet; UV - Ultraviolet

592323
5924 | Int J Pharm Sci Nanotech Vol 15; Issue 2, March−April 2022

freeform technology. 3D printing uses computerized It is an effective strategy to overcome some of the
drafting technology and programming to produce a 3D challenges of conventional pharmaceutical unit
object. The material is first ejected from a printer head operations (O Oyewumi, 2015). 3D printing technology
onto an x-y plane for creating the foundation of the has enabled unprecedented flexibility in the design and
object. Then the printer moves along the z-axis, and a manufacturing of complex objects, which can be utilized
liquid binder is ejected onto the base of the object to a in personalized and programmable medicine (Jose and
certain thickness. This process is repeated following the GV, 2018).
computer-aided drafting instructions until the object is In 3D printing, solid oral dosage forms can be printed
built layer by layer. After treatment, the unbound in a wide range of dosages release profiles, geometrics,
substrate is removed and the object is obtained (Maulvi, and size by simply modifying a digital model which
2019; Ursan, Chiu, and Pierce, 2013; Parulski et al., provides patients with tailored therapies. 3D printing
2021). can play a significant role in multiple active ingredient
The introduction of 3D printing technology in the dosage forms, where the formulation can be as a single
pharmaceutical industry has opened new horizons in the blend or multi-layer printed tablets with sustained-
research and development of printed materials and release properties. It reduces the frequency and number
devices. (Beg et al., 2020) Its main benefit lies in the of dosage form units consumed by the patient on a daily
production of small batches of medicines each with routine. 3D printing technology has high potential in
tailored dosages, shapes, sizes, and release individualized dosage form concept called the poly-pill
characteristics. concept. This brings about the possibility of all the drugs
In contrast to the conventional method 3D printing is required for the therapy into a single dosage form unit
more automated rapid and easy to use, customized, (Jose and GV, 2018; Gaurav et al., 2021).
sophisticated, and cost-effective (Solanki et al., 2018; Various techniques of additive manufacturing are
Singh et al., 2021). Indeed, the punches and dies-based such as powder bed-inkjet 3D printing, pressure-assisted
conventional tableting machines are fabricated for a micro syringe 3D printing, fused deposition modeling,
mass-production market and therefore lack in flexibility. selective laser sintering, stereolithography, etc (Jacob
3D printing on the other hand provoked much interest in et al., 2020).
pharmaceutics due to its large flexibility making it a Conventional Manufacturing - Conventional
promising tool to produce customized drug delivery manufacturing includes several steps as shown in
devices including solid oral dosage forms. Moreover, the figure 1.
most diversified and sophisticated drug delivery devices
Additive Manufacturing - Additive Manufacturing
for oral, dermal, and implantable administration can be
comprises the steps as shown in figure 2.
produced with high accuracy using 3D printers.

API-Exipient Preformulati Development Characterizat


Dispense
selection on optimization ion

Fig. 1. Conventional Manufacturing.

API- Patient
3D-
Exipient requireme Dispense
Printing
selection nt

Fig. 2. Additive Manufacturing.


Mandloi et al: 3D Printing for Drug Delivery and its Pharmaceutical Applications – Recent Findings and Challenges | 5925

medication, designed to disintegrate in the mouth with


Background just a sip of liquid (Vaz and Kumar, 2021).

The 3D printing technology was first introduced in the


late 1980s, during that time it was called Rapid Inventions of 3D Printing
Prototyping technology. This is because the process was
originally conceived as a fast and more cost-effective Several inventions of 3D printing are shown in figure 3.
method for product development within the industry.
The origin of 3D printing can be traced back to 1986
when the first patent was issued for stereolithography
Basic Procedure Involved in 3D Printing
apparatus (SLA) belonged to Chuck Hull. He is also
considered the father of 3D printing technology (Jamróz 3D printing has several types such as Fused Deposition
et al., 2018; Parulski et al., 2021). Modeling (FDM), Thermal Inkjet (TIJ) Printing,
Stereolithography, Selective Laser Sintering (SLS).
The first 3D printing technique used in
pharmaceutics was achieved by inkjet printing (Konta, In 3D printing first, the product is designed using
García-Piña, and Serrano, 2017; Chandekar et al., 2019). Computer-Aided Design (CAD) or animation modeling
This first happened in the early 90s at the Massachuset software. Then the design is converted into a 3D printer
Institute Technology invented and patented by Sachs et readable format which depicts the outer surface of the 3D
al (Vinchurkar, 2018). printed dosage form.
In 2015, Food and Drug Administration (FDA) The computer program then slices this surface into
approved the first 3D printed drug Spritam several printable layers which are transferred layer by
(levetiracetam) tablet for oral use. Aprecia layer to the 3D printer. As illustrated in Fig 4. Some
pharmaceutical produced the first 3D printed dosage products may require post-processing steps such as
form (tablet) using the Zipdose technology. Spritam is polishing and drying. Unused materials can be recycled
the orodispersible formulation of the high-dose to reuse for another printing cycle (Haris et. al.,2020).

First FDA
Inkjet photo-
First 3DP approved
polymerization
prosthetic 3DP drug
based printing
leg product
SLS Powder Bed printing First 3DP (Spritam)
SLA exoskeleton

1984 1986 1988 1992 1996 2000 2002 2008 2012 2014 2015 2018

First Introduction
functional First
FDM First Inkjet Printer prosthetic of 4D
miniature printing
3D printed jaw
kidney

Fig. 3. Inventions of 3D Printing.

Pharmaceutical product is Computer programs such as cura 3D printers such as FDM, SLS, SLA
designed through computer aided ultimaker, slices the surfaces and then prints the product layer by
design (CAD) transfers to the 3D printer layer

Fig. 4. Steps Involved in A 3D Printed Dosage Form.


5926 | Int J Pharm Sci Nanotech Vol 15; Issue 2, March−April 2022

3D
PRINTER

Powder Extrusion based


Liquid solidification
solidification systems

Drop on drop Selective laser Drop on solid Fused deposition Pressure assisted
Stereolithography
deposition sintering deposition modelling syringe

Fig. 5. 3D Printing Technologies for Medicine Manufacture.

Ability to
create tablets
of any shape
and size

Ability to set
Ability to
the dosage
print small
individually
batches of
for each
drugs
patient
BENEFITS OF 3D
TECHNOLOGY IN
PHARMACEUTICAL
FIELD
Ability to
replace a
Eco-friendly
large number
production
of drugs with
one tablet
Ability to
control the
process of
release of
active
substances

Fig. 6. Benefits of 3D Technology in Pharmaceutical Field.


Mandloi et al: 3D Printing for Drug Delivery and its Pharmaceutical Applications – Recent Findings and Challenges | 5927

Absence of
Numerous Knowledge
Material
Absence of
Printing using
Industry
same Device
Particular
lead to
Overhaul

Restricted to
Minor
Global 3-D Printing
on Patent
Implementa-
Components
Challenges tion

Changing of
long
Adminstrative
Established
Consistence
Manufacturin
g Processes Hardware &
Expensive to
Function

Fig. 7. Global Challenges of 3D Printing Technology.

Unique
Dosage
Forms
Personalize
Drug
d Drug
Testing
Dosing

Medical Complex
Low cost of Applications Drug
Production of 3-D Release
printing Profile

Anatomical
Rapid Models for
Prototyping Surgical
Preprations
Bio-Printing
of Tissues
and Organs

Fig. 8. Applications of 3D Printing Technology.


5928 | Int J Pharm Sci Nanotech Vol 15; Issue 2, March−April 2022

3D printing is in its initial phase in the liquid plastic material is transformed into a 3D
pharmaceutical industry on the other hand it is more object, layer by layer. It uses a laser as the power
advanced in the field of automobile, aerospace, source. (Horst, 2018).
biomedical, and tissue engineering. Advantages:
1. Speed

Main Components of a 3D Printer


2. Suitable to all other types of 3D printing
technology, high accuracy as well as resolution.
3. Prototypes and designs made with
The basic components of a 3D printer are- stereolithography are strong enough to be
(i) Print Bed (Tray): It is a type of flat surface where machined.
the 3D models are layered at the time of printing. Disadvantages:
Heated printed beds are used to avoid perverting 1. Time-consuming.
during the layering procedure.
2. Costly equipment.
(ii) Extruder: Extruder passes the plastic filament
3. Post-printing curing required (Mule et al., 2020;
inside the hot-end, which is its main function. It is
Deshmane et al., 2021; Vaz and Kumar, 2021).
the plunge-out part. The binal extruder is used in
3. Selective Laser Sintering: It is similar to
some types of printers, which the can print two
stereolithography. However, Selective is based
different materials at the same time.
upon the principle of laser-induced heating of
(iii) Hot-end: Hot-end is formed due to the heat caused.
powder particles. (Mohapatra et al., 2022).
The filament is poured between the temperature
Advantages:
sensor and an extrusion edge for the deposition of
fused material. Printing accuracy depends upon the 1. Easily reproducible and manageable.
nozzle size i.e., printing is more appropriate via a 2. Fastest process for printing functional durable,
smaller nozzle. prototypes or end-user parts.
(iv) Filament: Similar to the inkjet ink, the 3D printer 3. Wide variety of materials with characteristics of
is fed melted filament. It is used as the absorption strength, durability, and functionality.
material (Mule et. al., 2020). Disadvantages:
1. Requires post-printing finishing procedure.
2. Speed for interaction is restricted.
Types of 3D Printers 3. Due using of more energy inputs leads to
degradation starting materials (Vaz et. al.,2021;
1. Fused Deposition Modeling (FDM): Fused Haris et. al.,2020; Mule et. al.,2020).
Deposition Modeling is based upon the principle of 4. Inkjet Printing: Inkjet printing utilizes
extrusion of molten thermoplastics. It utilizes electromagnet, heat, and piezoelectric technology
thermoplastic polymers such as polyvinyl acetate to force ‘ink’ onto a material, i.e., polymer powder
(PVA), Acrylonitrile butadiene styrene (ABS) in a bed on the stage (Nandi, 2020; Thakur and
semi-molten form. Here, objects are built by Murthy, 2021).
heating a thermoplastic filament to its melting Advantages:
point and extruding the thermoplastic layer by 1. Simultaneous printing with multiple materials.
layer (Araújo et al., 2019; Cailleaux et al., 2021). 2. High resolution and smooth surface finish.
Advantages: 3. Printing over a large area.
1. Printing cost is less and available extensively. Disadvantages:
2. Plastic material is used hence it is cheaper. 1. Limited material selection.
3. There is no unbound loose powder. 2. Low part strength compared to bulk materials.
4. There is no solvent removal required. 3. Substrate requirements (Vaz et. al.,2021; Haris
5. Friability and uniformity of drug are high. et. al.,2020; Mule et. al.,2020).
Disadvantages:
1. Due to high-temperature deterioration of starting
material can happen. Different Methods Used in 3d Printing
2. The printing quality is not like those by SLA/SLS.
3. For support leave marks removal and sanding is Different methods used in 3D printing are mentioned in
required. Table 1.
4. Layer by layer printing might sometimes lead to a
problem with wrapping and minor shrinking
(Bhattacharya et al., 2019; Melocchi et al., 2020; Polymers Used in 3d Printing
Mule et al., 2020; Wei et al., 2020; Vaz and
Kumar, 2021). Different polymers used in 3D printing are mentioned in
2. Stereolithography (SLA): Stereolithography uses Table 2.
liquid plastic as the source material and this
Mandloi et al: 3D Printing for Drug Delivery and its Pharmaceutical Applications – Recent Findings and Challenges | 5929

Table 1. Different Methods Used in 3D Printing. • Shows flexibility in formulation


S. Starting • Environment friendly (Jose and GV, 2018;
Method Principle References
No. Material Bakhatwar and Chikkala, 2019; Ali, Ahmad, and
Extrusion of
(Araújo et al., Akhtar, 2020; Abaci et al., 2021)
2019;
1. FDM Filament molten
Cailleaux
thermoplastics
et al., 2021) Disadvantages of 3D Printing
UV initiated • Scope for the manufacturing of illegal drugs
(Horst, 2018;
Liquid curing of
2. SLA
photopolymer defined photo
Deshmane • Regulatory concern
et al., 2021)
resin layers. • Violation of Copyrights
Laser induced (Vaz and • Low yield (Thakur and Murthy, 2021)
heating of Kumar, 2021; • Limited Size
3. SLS Powder
powder Mohapatra
particles. et al., 2022) • Limited Raw Materials (Ngo et al., 2018;
Drop on (Haris et al., Bhattacharya et al., 2019; Lamichhane et al.,
4. Inkjet Powder demand binder 2020; Mule 2019)
printing. et al., 2020)

Recent Researches of 3D Printing in the


Table 2. Polymers used in 3D Printing

Pharmaceutical Field
Polymer Drug Delivery System References

(Tagami et al.,
Poly vinyl alcohol
Tablets, Capsule 2017; Wei et al., In the past several years there have been several types of
(PVA)
2020)
research conducted in the pharmaceutical field for
(Chi et al., dosage forms such as, in the year 2019 Tagami et. al.
Polylactic acid (PLA) Nanofibers
2020) showed that the organic solvent type, temperature, and
(GV et al., 2017; drug concentration greatly affects the drug loading and
Polycaprolactone Tablets, carbon around 5% curcumin can be incorporated into the PVA
Ho
(PCL) nanotubes
et al., 2017) filament using the soaking method (Tagami et al., 2019).
Hydroxypropyl In the year 2020, Asmari et. al. conducted a study for the
(Cheng et al.,
methylcellulose Matrix tablets
2020) comparison of dissolution profiles using 3D printed PVA
(HPMC)
and commercial paracetamol tablets (Asmari, Sil, and
(Loureiro and Patel, 2020). In the year 2019 Wei et. al. performed a
Poly(lactic-co-glycolic Microsphere, capsules, Pereira, 2020;
acid) (PLGA) tablets, nanospheres Serris et al., study, in this study, the processability of PVA into melt-
2020) extruded filaments and then into 3D printed tablets by
(Beck et al., FDM was studied (Wei et al., 2020). In the year 2020,
Poly(methacrylate)
(Eudragit)
Nano capsules, Tablets 2017; dos Santos Macedo et. al. conducted a study and the aim was to
et al., 2021) evaluate the processability of PVA-based filaments
(Homaee containing paracetamol made by hot-melt extrusion for
Ethyl cellulose (EC) Tablets Borujeni
fused deposition modeling (Macedo et al., 2020).
et al., 2020)

(Borandeh et al.,
Polyurethane (PU) Tablets, Hydrogel
2021) Application of 3D Printing in the
Poly(methyl
methacrylate) Tablets
(Petersmann et Pharmaceutical Field
al., 2019)
(PMMA)
1. Rapid prototyping: It is used to create a real scale
Advantages of 3D Printing model of an object in a short lead time, using
Computer-Aided Design (CAD)
• High drug loading ability. 2. In the healthcare sector: Tools can be prepared for
• Cost reduction. surgery, medicines can be manufactured (Al-
• Customized and Personalized medication (Pandey Dulimi et al., 2021)
et al., 2020) 3. Reconstituting bones and body parts in forensic
• Accurate and precise dosing of potent drugs. pathology: Fingerprint examination, accident
• Enhanced productivity. reconstruction, structural, and industrial
accidents
• Treatment can be customized to improve patient
adherence, in the case of multidrug therapy with 4. Drug testing: It can fabricate complex geometries
multiple dosing regimens. to achieve various drugs releasing kinetics (Parhi,
2021)
• Suitable drug delivery for difficult to formulate
active ingredients.
5930 | Int J Pharm Sci Nanotech Vol 15; Issue 2, March−April 2022

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