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3D Printing of Pharmaceutical
and Drug Delivery Devices
ADVANCES IN PHARMACEUTICAL TECHNOLOGY
A Wiley Book Series
Series Editors:
Dennis Douroumis, University of Greenwich, UK
Alfred Fahr, Friedrich–Schiller University of Jena, Germany
Jűrgen Siepmann, University of Lille, France
Martin Snowden, University of Greenwich, UK
Vladimir Torchilin, Northeastern University, USA
Titles in the Series
Hot-Melt Extrusion: Pharmaceutical Applications
Edited by Dionysios Douroumis
Drug Delivery Strategies for Poorly Water-Soluble Drugs
Edited by Dionysios Douroumis and Alfred Fahr
Computational Pharmaceutics: Application of Molecular Modeling in Drug Delivery
Edited by Defang Ouyang and Sean C. Smith
Pulmonary Drug Delivery: Advances and Challenges
Edited by Ali Nokhodchi and Gary P. Martin
Novel Delivery Systems for Transdermal and Intradermal Drug Delivery
Edited by Ryan Donnelly and Raj Singh
Drug Delivery Systems for Tuberculosis Prevention and Treatment
Edited by Anthony J. Hickey
Continuous Manufacturing of Pharmaceuticals
Edited by Peter Kleinebudde, Johannes Khinast, and Jukka Rantanen
Pharmaceutical Quality by Design
Edited by Walkiria S. Schlindwein and Mark Gibson
In Vitro Drug Release Testing of Special Dosage Forms
Edited by Nikoletta Fotaki and Sandra Klein
Characterization of Pharmaceutical Nano- and Microsystems
Edited by Leena Peltonen
Biopharmaceutics: From Fundamentals to Industrial Practice
Edited by Hannah Batchelor
3D Printing of Pharmaceutical and Drug Delivery Devices: Progress from Bench to
Bedside
Edited by Dimitrios A. Lamprou, Dennis Douroumis, and Sheng Qi
Forthcoming Titles:
Process Analytics for Pharmaceuticals
Edited by Jukka Rantanen, Clare Strachan and Thomas De Beer
Mucosal Drug Delivery
Edited by Rene Holm
3D Printing of
Pharmaceutical and
Drug Delivery Devices
Progress from Bench to Bedside
Edited by
DIMITRIOS A. LAMPROU
Queen’s University Belfast
Liburn Road, Belfast, United Kingdom
DENNIS DOUROUMIS
School of Science, University of Greenwich
Medway Campus, Central Avenue
Chatham Maritime, United kingdom
SHENG QI
University of East Anglia
Norwich Research Park, United Kingdom
This edition first published 2024
© 2024 John Wiley & Sons Ltd.
All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted, in any form or by
any means, electronic, mechanical, photocopying, recording or otherwise, except as permitted by law. Advice on how to obtain
permission to reuse material from this title is available at http://www.wiley.com/go/permissions.
The right of Dimitrios A. Lamprou, Dennis Douroumis, and Sheng Qi to be identified as the authors of this work / the editorial
material in this work has been asserted in accordance with law.
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John Wiley & Sons, Inc., 111 River Street, Hoboken, NJ 07030, USA
John Wiley & Sons Ltd, The Atrium, Southern Gate, Chichester, West Sussex, PO19 8SQ, UK
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other damages.
A catalogue record for this book is available from the Library of Congress
Hardback ISBN: 9781119835974; ePub ISBN: 9781119835981; ePDF ISBN: 9781119835998; oBook ISBN: 9781119836001
Cover Image: © Pixel B/Shutterstock
Cover Design: Wiley
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“There is nothing impossible to those who dare - (ΟU
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- Alexander the Great”
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Contents
About the Editors xv
List of Contributors xvii
Series Preface xxi
Preface xxiii
1 Materials for 3D Printing 1
Thomas McDonagh, Bin Zhang and Sheng Qi
1.1 Introduction 1
1.2 Material Processability Considerations for Pharmaceutical 3DP 2
1.2.1 Thermal Extrusion-Based 3D Printing 2
1.2.1.1 Thermal Considerations 3
1.2.1.2 Solubility Enhancement 4
1.2.1.3 Mechanical Considerations 4
1.2.2 Semi-Solid Extrusion 3DP 5
1.2.2.1 Rheological Considerations 6
1.2.2.2
Example Applications 7
1.2.3 Powder Bed Fusion 3D Printing 7
1.2.3.1 Powder Flowability Considerations 9
1.2.3.2 Powder Packing Density Considerations 10
1.2.3.3 Powder Energy Absorbance Considerations 10
1.2.4 Stereolithography 3D Printing 11
1.3 Classification of Common Materials Used in Pharmaceutical 3DP 14
1.3.1 Alcohol Derived Polymers 14
1.3.2 Eudragits 14
1.3.3 Other Polymers 15
1.3.4 Graft Polymers 16
1.3.5 Photocrosslinkable 16
1.3.6 Natural Materials 16
1.3.7 Lipid Materials 17
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viii Contents
1.4 Conclusions and Future Perspectives 19
References 19
2 The Use of Microstructure Design and 3D Printing for Tailored
Drug Release 29
Bin Zhang, Thomas McDonagh, Joey Yan, Andy Glendale, Richard Bib,
Peter Belton and Sheng Qi
2.1 Introduction 29
2.2 3D-Printing Technologies 30
2.3 3D Design for Drug-Loaded Device 33
2.3.1 CAD Design-Based Design 34
2.3.2 Computational Software-Based Design 34
2.3.3 3D-Printing Parameter-Based Design 35
2.3.4 Polypills and Complex Designs 35
2.4 3D Designs Influence Drug Release 36
2.4.1 Controlling Drug Release 36
2.4.2 Modifying Drug Release 38
2.5 Challenges and Perspective 39
References 40
3 3D Printing of Oral Solid Dosage Forms Using Selective Laser Sintering 43
Atabak, Tabriz Ghanizadeh, Hannah Kuofie, James Scoble, Sam Boulton and
Dennis Douroumis
3.1 Introduction 43
3.2 Operational Principles of Selective Laser Sintering 46
3.2.1 Manufacturing Challenges for SLS 47
3.2.2 Laser Selection and Scanning Speed 48
3.2.3 Powder Material Parameters 49
3.2.4 Powder Bed and Recoater Parameters 50
3.3 3D-Printed Oral Dosages 50
3.4 Advantages of SLS 59
3.4.1 Printing Features 59
3.4.2 Control of Surface Properties 59
3.4.3 Printing of Complex Geometries 59
3.4.4 Using a Wide Range of Materials 60
3.4.5 Drug Loading and Dose Combinations 60
3.4.6 Personalised Dosage Forms 60
3.4.7 SLS Disadvantages 61
3.5 Conclusions 61
References 61
4 3D Printing for Medical Device Applications 65
Jian-Feng Zhang, Bernabe Tucker, John Tipton, Mahrokh Dadsetan, Scott Jones,
Andrea Engel, Theresia Kuntz and Cecile Boudot
4.1 Introduction 65
4.2 3D Printers 66
4.2.1 SLA 67
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Contents ix
4.2.2 FFF 68
4.2.3 Selective Laser Sintering (SLS) 69
4.3 Biomaterials for 3D-Printed Medical Devices 69
4.3.1 Bioresorbable Polymers 69
4.3.1.1 Synthetic Bioresorbable Polymers 70
4.3.1.2 Natural Bioresorbable Polymers 72
4.3.2 Non-Bioresorbable Polymers 72
4.3.3 Smart Polymers 73
4.3.4 Metal and Ceramic 75
4.4 3D-Printed Personalised Medical Devices 76
4.4.1 Vascular Repair Devices 77
4.4.2 Splints 77
4.4.3 Nerve Guidance Conduits 78
4.4.4 Tissue Engineering 78
4.4.5 3D Printing in Dentistry 79
4.4.6 3D-Printed Orthopaedic Devices 80
4.5 Regulatory 81
4.6 Future Perspectives 83
References 84
5 3D Printed Implants for Long-Acting Drug Delivery 89
Aikaterini Dedeloudi, Sune Andersen, Peyton Hopson and Dimitrios A. Lamprou
5.1 Introduction 89
5.2 Types of 3D-Printed Scaffolds 90
5.2.1 Implantable Scaffolds 90
5.2.1.1 Passive Implants 90
5.2.1.2 Active Implants 92
5.2.2 Injectable Scaffolds 92
5.2.3 Innovative 3D-Printed Scaffolds 93
5.3 Critical Parameters in Designing 3D-Printed Implantable Scaffolds 94
5.3.1 Structural Characteristics 94
5.3.1.1 Geometry of Implants 95
5.3.1.2 Porosity Properties and Pore Features 95
5.3.1.3 Surface Properties 96
5.3.2 Mechanical Properties 96
5.3.3 Biological and Physiological Parameters 96
5.3.3.1 Cellular Adhesion 96
5.3.3.2 Absorption and Degradation Rates 97
5.3.3.3 Biocompatibility Aspects 97
5.4 Critical Parameters in Selecting Materials for 3D-Printed Scaffolds 97
5.4.1 Materials Used in 3D-Printed Long-Acting Scaffolds 99
5.4.1.1 Natural Polymers 99
5.4.1.2 Synthetic Polymers 99
5.4.1.3 Ceramics and Metals 100
5.4.1.4 Composites 100
References 108
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