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2 Fused Deposition Modeling (FDM) of Pharmaceuticals 87
and rheological behaviour. These limitations might lengthen the research and
development phase of printed dosage forms and hamper their clinical translation.
Adaptations of existing equipment, invention of new feeding approaches or development of new feedstock material could facilitate tapping into its full potential
(Abdelhamid et al.,
In 2015, the first 3D-printed product received FDA approval. The product,
called Spiritam, was developed by Aprecia Pharmaceuticals using the ZipDose
technology with powder 3D-printing. It was an orodispersible tablet loaded with
levetiracetam for the treatment of epilepsy. Despite this earlier approval, there are
unfortunately no regulatory guidelines available yet for 3D-printed drug products.
Development of universal guidelines implies a strenuous task due to the variety of
3D-printing techniques and personalization of its products. Individual efficiency and
risk assessment for each developed product might be required, which could hamper
fast implementation in healthcare. Moreover, ambiguity exists about whether or not
3D-printing classifies as production or compounding technique, which will greatly
affect regulatory requirements (Auriemma et al.,
Another aspect to keep in mind is the fact that the production rate of FDM 3Dprinting is rather slow in comparison with traditional manufacturing techniques,
making the technique unsuitable for mass production. Flexible, batch-wise production remains one of the strengths of FDM 3D-printing (Parulski et al.,
it is anticipated that 3D-printing will not entirely replace traditional manufacturing
but act as a complementary production technique, suitable for specific cases where
personalization is highly desirable.
2022; Henry et al., 2021a)
2022).
2021). Hence,
2.7 Conclusion
In the recent years, fused deposition modeling 3D-printing has become a popular technology in the field of pharmaceutical research. While the process itself
seems simple, its implementation in pharmaceutical production is challenging.
The mechanical properties and viscoelastic behaviour of the feedstock material
dictate its processability with the FDM printer, limiting the portfolio of applicable
pharmaceutical materials. Addition of processing aids or blending of polymers
might strengthen the filament or lower its viscosity, hence resulting in new,
printable formulations. The development of screening tools like tensile tests or small
amplitude oscillatory shear tests might enable a structured investigation of complex
formulations, while avoiding costly and time-consuming trial-and-error approaches.
Alternatively, melt printing techniques utilizing alternative feedstock materials (e.g.
pellets, powders) are also under development.
Once a printable formulation has been developed, personalization of the drug
product by designing a tailored dosage form and incorporating a specific drug
(load) becomes decisive. Both in-silico model parameters and process settings
should be optimized to obtain a qualitative end-product with acceptable mechanical
properties and the required drug release profile. A variety of traditional and novel
88 S. Henry et al.
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characterization techniques have been explored for 3D-printed drug products to
ensure that quality is built-in into the process.
The potential of FDM 3D-printing has been confirmed by numerous research
groups through development and characterization of miscellaneous innovative
dosage forms like oral tablets, transdermal films or implants. Nonetheless, before
this technique can be fully implemented to produce personalized dosage forms
on-site, the efficiency and reliability of 3D printers should be improved. Gradual
optimization of the production process and expansion of the proficiency for printing
by researchers might enable this technique to truly revolutionize pharmaceutical
manufacturing.
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