3D PRINTING IN PHARMACEUTICALS: TRANSFORMING DRUG FORMULATION AND PERSONALIZED MEDICINE

Authors

DOI:

https://doi.org/10.22159/ijpps.2025v17i8.54888

Keywords:

Fused deposition modeling, Stereolithography, SLS, One size fits all

Abstract

Three-dimensional printing is poised to transform the landscape of pharmaceutical manufacturing by enabling the tailored production of medicines that cater to individual patient requirements. Emphasizing its notable contributions to personalized medicine, this review explores the foundational principles and methods of 3D printing in drug delivery. Key methods, including Fused Deposition Modeling (FDM), Selective Laser Sintering (SLS), stereolithography (SLA), and semi-solid extrusion, are evaluated for their benefits and difficulties. The study shows how 3D printing overcomes the bounds of conventional manufacturing techniques, including one-size-fits-all and rigid dosing, thereby enabling the on-demand production of complex dosage forms with customized drug release properties and improved solubility for difficult compounds. Along with the historic FDA clearance of SPRITAM®, the first 3D-printed medicine, practical applications have been demonstrated in the production of pediatric mini-tablets, geriatric polypills, and multi-compartment capsules. Moreover, the study discusses how customized implantable devices, bioprinting, and 3D printing are progressively integrated. Although problems, including material compatibility, process standardization, and legal obstacles, still exist, the rapid development rate promises a future in which 3D printing is essential to pharmaceutical practice. It has great potential to enhance therapeutic results and patient quality of life substantially.

Downloads

Download data is not yet available.

References

1. Wang S, Chen X, Han X, Hong X, Li X, Zhang H. A review of 3D printing technology in pharmaceutics: technology and applications now and future. Pharmaceutics. 2023 Jan 26;15(2):416. doi: 10.3390/pharmaceutics15020416, PMID 36839738.

2. Personalized medicine coalition. The personalized medicine report opportunity challenges and the future. In: Washington, DC: Personalized Medicine Coalition; 2020 Available from: https://www.personalizedmedicinecoalition.org/Userfiles/PMC-Corporate/file/PMC_The_Personalized_Medicine_Report_Opportunity_Challenges_and_the_Future.pdf.

3. Cheng JT, Tan EC, Kang L. Pharmacy 3D printing. Biofabrication. 2024 Oct 24;17(1):012002. doi: 10.1088/1758-5090/ad837a, PMID 39366411.

4. Jennotte O, Koch N, Lechanteur A, Evrard B. Three-dimensional printing technology as a promising tool in bioavailability enhancement of poorly water-soluble molecules: a review. Int J Pharm. 2020 Apr 30;580:119200. doi: 10.1016/j.ijpharm.2020.119200, PMID 32156531.

5. Yu DG, Zhu LM, Branford White CJ, Yang XL. Three-dimensional printing in pharmaceutics: promises and problems. J Pharm Sci. 2008 Sep;97(9):3666-90. doi: 10.1002/jps.21284, PMID 18257041.

6. Buyukgoz GG, Kossor CG, Dave RN. Enhanced supersaturation via fusion-assisted amorphization during FDM 3D printing of crystalline poorly soluble drug-loaded filaments. Pharmaceutics. 2021 Nov 4;13(11):1857. doi: 10.3390/pharmaceutics13111857, PMID 34834272.

7. Tripathi S, Mandal SS, Bauri S, Maiti P. 3D bioprinting and its innovative approach for biomedical applications. Med. 2023;4(1):e194. doi: 10.1002/mco2.194, PMID 36582305, PMCID PMC9790048.

8. Nandi S. 3D printing of pharmaceuticals leading trend in pharmaceutical industry and future perspectives. Asian J Pharm Clin Res. 2020 Dec 7;13(6):10-6. doi: 10.22159/ajpcr.2020.v13i12.39584.

9. Bg PK, Mehrotra S, Marques SM, Kumar L, Verma R. 3D printing in personalized medicines: a focus on applications of the technology. Mater Today Commun. 2023 Jun;35:105875. doi: 10.1016/j.mtcomm.2023.105875.

10. Vanaei S, Parizi MS, Vanaei S, Salemizadehparizi F, Vanaei HR. An overview on materials and techniques in 3D bioprinting toward biomedical application. Engineered Regeneration. 2021;2:1-18. doi: 10.1016/j.engreg.2020.12.001.

11. Singhvi G, Patil S, Girdhar V, Chellappan DK, Gupta G, Dua K. 3D-printing: an emerging and revolutionary technology in pharmaceuticals. Panminerva Med. 2018 Dec;60(4):170-3. doi: 10.23736/S0031-0808.18.03467-5, PMID 29856179.

12. Araujo MR, Sa Barreto LL, Gratieri T, Gelfuso GM, Cunha Filho M. The digital pharmacies era: how 3D printing technology using fused deposition modeling can become a reality. Pharmaceutics. 2019 Mar 19;11(3):128. doi: 10.3390/pharmaceutics11030128, PMID 30893842.

13. Chai X, Chai H, Wang X, Yang J, Li J, Zhao Y. Fused deposition modeling (FDM) 3D printed tablets for intragastric floating delivery of domperidone. Sci Rep. 2017 Jun 6;7(1):2829. doi: 10.1038/s41598-017-03097-x, PMID 28588251.

14. Lakkala P, Munnangi SR, Bandari S, Repka M. Additive manufacturing technologies with emphasis on stereolithography 3D printing in pharmaceutical and medical applications: a review. Int J Pharm X. 2023 Jan 3;5:100159. doi: 10.1016/j.ijpx.2023.100159, PMID 36632068, PMCID PMC9827389.

15. Healy AV, Fuenmayor E, Doran P, Geever LM, Higginbotham CL, Lyons JG. Additive manufacturing of personalized pharmaceutical dosage forms via stereolithography. Pharmaceutics. 2019 Dec 3;11(12):645. doi: 10.3390/pharmaceutics11120645, PMID 31816898.

16. Kushwaha S. Application of hot melt extrusion in pharmaceutical 3D printing. J Bioequiv Availab. 2018 Jan 1;10(3):379. doi: 10.4172/0975-0851.1000379.

17. Zhou Y, Ji M, Wang L, Deng F, Cheng S, Li X. POS1361 a novel oral 3D-printed delayed and extended release tofacitinib (T19) for the treatment of rheumatoid arthritis and related inflammatory diseases. Ann Rheum Dis. 2024 Jun;83 Suppl 1:592. doi: 10.1136/annrheumdis-2024-eular.1022.

18. Safhi AY. Three-dimensional (3D) printing in cancer therapy and diagnostics: current status and future perspectives. Pharmaceuticals (Basel). 2022;15(6):678. doi: 10.3390/ph15060678, PMID 35745597.

19. Kantaros A. 3D printing in regenerative medicine: technologies and resources utilized. Int J Mol Sci. 2022 Jan;23(23):14621. doi: 10.3390/ijms232314621, PMID 36498949.

20. Sinha P, Lahare P, Sahu M, Cimler R, Schnitzer M, Hlubenova J. Concept and evolution in 3D printing for excellence in healthcare. Curr Med Chem. 2025;32(5):831-79. doi: 10.2174/0109298673262300231129102520, PMID 38265395.

21. Huang J, Ware HO, Hai R, Shao G, Sun C. Conformal geometry and multimaterial additive manufacturing through freeform transformation of building layers. Adv Mater. 2021;33(11):e2005672. doi: 10.1002/adma.202005672, PMID 33533141.

22. Cailleaux S, Sanchez Ballester NM, Gueche YA, Bataille B, Soulairol I. Fused deposition modeling (FDM) the new asset for the production of tailored medicines. J Control Release. 2021 Feb;330:821-41. doi: 10.1016/j.jconrel.2020.10.056, PMID 33130069.

23. Charoo NA, Barakh Ali SF, Mohamed EM, Kuttolamadom MA, Ozkan T, Khan MA. Selective laser sintering 3D printing an overview of the technology and pharmaceutical applications. Drug Dev Ind Pharm. 2020 May 13;46(6):869-77. doi: 10.1080/03639045.2020.1764027, PMID 32364418.

24. Dumpa N, Butreddy A, Wang H, Komanduri N, Bandari S, Repka MA. 3D printing in personalized drug delivery: an overview of hot melt extrusion-based fused deposition modeling. Int J Pharm. 2021 May;600:120501. doi: 10.1016/j.ijpharm.2021.120501, PMID 33746011.

25. FG, Velez A. 3D pharming: direct printing of personalized pharmaceutical tablets. Polym Sci. 2016;2(1):100011. doi: 10.4172/2471-9935.100011.

26. Goyanes A, Wang J, Buanz A, Martinez Pacheco R, Telford R, Gaisford S. 3D printing of medicines: engineering novel oral devices with unique design and drug release characteristics. Mol Pharm. 2015 Oct 16;12(11):4077-84. doi: 10.1021/acs.molpharmaceut.5b00510, PMID 26473653.

27. Okafor Muo OL, Hassanin H, Kayyali R, ElShaer A. 3D printing of solid oral dosage forms: numerous challenges with unique opportunities. J Pharm Sci. 2020 Dec;109(12):3535-50. doi: 10.1016/j.xphs.2020.08.029, PMID 32976900.

28. Pietrzak K, Isreb A, Alhnan MA. A flexible dose dispenser for immediate and extended release 3D printed tablets. Eur J Pharm Biopharm. 2015 Oct;96:380-7. doi: 10.1016/j.ejpb.2015.07.027, PMID 26277660.

29. Rahman Z, Charoo NA, Kuttolamadom M, Asadi A, Khan MA. Printing of personalized medication using binder jetting 3D printer. In: Precision medicine for investigators, practitioners and providers. Elsevier; 2020. p. 473-81. doi: 10.1016/B978-0-12-819178-1.00046-0.

30. Sadia M, Sosnicka A, Arafat B, Isreb A, Ahmed W, Kelarakis A. Adaptation of pharmaceutical excipients to FDM 3D printing for the fabrication of patient-tailored immediate release tablets. Int J Pharm. 2016 Nov;513(1-2):659-68. doi: 10.1016/j.ijpharm.2016.09.050, PMID 27640246.

31. Vaz VM, Kumar L. 3D printing as a promising tool in personalized medicine. AAPS PharmSciTech. 2021 Jan;22(1):30. doi: 10.1208/s12249-020-01905-8.

32. Glukhova SA, Molchanov VS, Chesnokov YM, Lokshin BV, Kharitonova EP, Philippova OE. Green nanocomposite gels based on binary network of sodium alginate and percolating halloysite clay nanotubes for 3D printing. Carbohydr Polym. 2022 Apr 15;282:119106. doi: 10.1016/j.carbpol.2022.119106, PMID 35123742.

33. Pund A, Magar M, Ahirrao Y, Chaudhari A, Amritkar A. 3D printing technology: a customized advanced drug delivery. Asian J Pharm Clin Res. 2022 Aug 7;15(8):23-33. doi: 10.22159/ajpcr.2022.v15i8.45136.

34. Melocchi A, Parietti F, Maroni A, Foppoli A, Gazzaniga A, Zema L. Hot melt extruded filaments based on pharmaceutical grade polymers for 3D printing by fused deposition modeling. Int J Pharm. 2016 Jul 25;509(1-2):255-63. doi: 10.1016/j.ijpharm.2016.05.036, PMID 27215535.

35. Macedo J, Marques R, Vervaet C, Pinto JF. Production of bi-compartmental tablets by FDM 3D printing for the withdrawal of diazepam. Pharmaceutics. 2023 Feb 6;15(2):538. doi: 10.3390/pharmaceutics15020538, PMID 36839860, PMCID PMC9960133.

36. Parulski C, Jennotte O, Lechanteur A, Evrard B. Challenges of fused deposition modeling 3D printing in pharmaceutical applications: where are we now? Adv Drug Deliv Rev. 2021 Aug;175:113810. doi: 10.1016/j.addr.2021.05.020, PMID 34029646.

37. Tan DK, Maniruzzaman M, Nokhodchi A. Advanced pharmaceutical applications of hot melt extrusion coupled with fused deposition modelling (FDM) 3D printing for personalised drug delivery. Pharmaceutics. 2018 Oct 24;10(4):203. doi: 10.3390/pharmaceutics10040203, PMID 30356002, PMCID PMC6321644.

38. Pesic N, Ivkovic B, Barudzija T, Grujic B, Ibric S, Medarevic D. Selective laser sintering 3D printing of carvedilol tablets: enhancing dissolution through amorphization. Pharmaceutics. 2024 Dec 24;17(1):6. doi: 10.3390/pharmaceutics17010006, PMID 39861659, PMCID PMC11768180.

39. Gueche YA, Sanchez Ballester NM, Cailleaux S, Bataille B, Soulairol I. Selective laser sintering (SLS) a new chapter in the production of solid oral forms (SOFs) by 3D printing. Pharmaceutics. 2021 Aug 6;13(8):1212. doi: 10.3390/pharmaceutics13081212, PMID 34452173, PMCID PMC8399326.

40. Charoo NA, Barakh Ali SF, Mohamed EM, Kuttolamadom MA, Ozkan T, Khan MA. Selective laser sintering 3D printing an overview of the technology and pharmaceutical applications. Drug Dev Ind Pharm. 2020 Jun;46(6):869-77. doi: 10.1080/03639045.2020.1764027, PMID 32364418.

41. Balasankar A, Anbazhakan K, Arul V, Mutharaian VN, Sriram G, Aruchamy K. Recent advances in the production of pharmaceuticals using selective laser sintering. Biomimetics (Basel). 2023 Jul 27;8(4):330. doi: 10.3390/biomimetics8040330, PMID 37622935.

42. Trenfield SJ, Januskaite P, Goyanes A, Wilsdon D, Rowland M, Gaisford S. Prediction of solid state form of SLS 3D printed medicines using NIR and Raman spectroscopy. Pharmaceutics. 2022 Mar 8;14(3):589. doi: 10.3390/pharmaceutics14030589, PMID 35335965, PMCID PMC8949593.

43. Awad A, Fina F, Goyanes A, Gaisford S, Basit AW. 3D printing: principles and pharmaceutical applications of selective laser sintering. Int J Pharm. 2020 Aug 30;586:119594. doi: 10.1016/j.ijpharm.2020.119594, PMID 32622811.

44. Trenfield SJ, Xu X, Goyanes A, Rowland M, Wilsdon D, Gaisford S. Releasing fast and slow: non-destructive prediction of density and drug release from SLS 3D printed tablets using NIR spectroscopy. Int J Pharm X. 2023 Dec;5:100148. doi: 10.1016/j.ijpx.2022.100148, PMID 36590827.

45. Reddy CV, VB, Venkatesh MP, Pramod Kumar TM. First FDA approved 3D printed drug paved new path for increased precision in patient care. ACCTRA. 2020;7(2):93-103. doi: 10.2174/2213476X07666191226145027.

46. Alqahtani AA, Ahmed MM, Mohammed AA, Ahmad J. 3D printed pharmaceutical systems for personalized treatment in metabolic syndrome. Pharmaceutics. 2023 Apr 5;15(4):1152. doi: 10.3390/pharmaceutics15041152, PMID 37111638, PMCID PMC10144629.

47. Wojtylko M, Lamprou DA, Froelich A, Kuczko W, Wichniarek R, Osmalek T. 3D-printed solid oral dosage forms for mental and neurological disorders: recent advances and future perspectives. Expert Opin Drug Deliv. 2024 Nov;21(11):1523-41. doi: 10.1080/17425247.2023.2292692, PMID 38078427.

48. Huang L, Yang W, Bu Y, Yu M, Xu M, Guo J. Patient-focused programable release indomethacin tablets prepared via conjugation of hot melt extrusion (HME) and fused depositional modeling (FDM)-3D printing technologies. J Drug Deliv Sci Technol. 2024 Aug 1;97:105797. doi: 10.1016/j.jddst.2024.105797.

49. Gaurkhede SG, Osipitan OO, Dromgoole G, Spencer SA, Pasqua AJ, Deng J. 3D printing and dissolution testing of novel capsule shells for use in delivering acetaminophen. J Pharm Sci. 2021 Dec;110(12):3829-37. doi: 10.1016/j.xphs.2021.08.030, PMID 34469748.

50. Khaled SA, Burley JC, Alexander MR, Roberts CJ. Desktop 3D printing of controlled release pharmaceutical bilayer tablets. Int J Pharm. 2014 Jan 30;461(1-2):105-11. doi: 10.1016/j.ijpharm.2013.11.021, PMID 24280018.

51. Khaled SA, Burley JC, Alexander MR, Yang J, Roberts CJ. 3D printing of tablets containing multiple drugs with defined release profiles. Int J Pharm. 2015 Oct 30;494(2):643-50. doi: 10.1016/j.ijpharm.2015.07.067, PMID 26235921.

52. Allahham N, Fina F, Marcuta C, Kraschew L, Mohr W, Gaisford S. Selective laser sintering 3D printing of orally disintegrating Printlets containing ondansetron. Pharmaceutics. 2020 Jan 30;12(2):110. doi: 10.3390/pharmaceutics12020110, PMID 32019101, PMCID PMC7076455.

53. Karavasili C, Zgouro P, Manousi N, Lazaridou A, Zacharis CK, Bouropoulos N. Cereal-based 3D printed dosage forms for drug administration during breakfast in pediatric patients within a hospital setting. J Pharm Sci. 2022 Sep;111(9):2562-70. doi: 10.1016/j.xphs.2022.04.013, PMID 35469835.

54. Okwuosa TC, Pereira BC, Arafat B, Cieszynska M, Isreb A, Alhnan MA. Fabricating a shell core delayed release tablet using dual FDM 3D printing for patient-centred therapy. Pharm Res. 2017 Feb;34(2):427-37. doi: 10.1007/s11095-016-2073-3, PMID 27943014.

55. Palekar S, Nukala PK, Mishra SM, Kipping T, Patel K. Application of 3D printing technology and quality by design approach for development of age-appropriate pediatric formulation of baclofen. Int J Pharm. 2019 Feb 10;556:106-16. doi: 10.1016/j.ijpharm.2018.11.062, PMID 30513398.

56. Krause J, Muller L, Sarwinska D, Seidlitz A, Sznitowska M, Weitschies W. 3D printing of mini tablets for pediatric use. Pharmaceuticals (Basel). 2021 Feb 11;14(2):143. doi: 10.3390/ph14020143, PMID 33670158, PMCID PMC7916857.

57. Ianno V, Vurpillot S, Prillieux S, Espeau P. Pediatric formulations developed by extrusion-based 3D printing: from past discoveries to future prospects. Pharmaceutics. 2024 Mar 22;16(4):441. doi: 10.3390/pharmaceutics16040441, PMID 38675103, PMCID PMC11054634.

58. Monou PK, Andriotis EG, Saropoulou E, Tzimtzimis E, Tzetzis D, Komis G. Fabrication of hybrid coated microneedles with donepezil utilizing digital light processing and semisolid extrusion printing for the management of alzheimers disease. Mol Pharm. 2024 Sep 2;21(9):4450-64. doi: 10.1021/acs.molpharmaceut.4c00377, PMID 39163171, PMCID PMC11372831.

59. Zgouro P, Katsamenis OL, Moschakis T, Eleftheriadis GK, Kyriakidis AS, Chachlioutaki K. A floating 3D printed polypill formulation for the coadministration and sustained release of antihypertensive drugs. Int J Pharm. 2024 Apr 25;655:124058. doi: 10.1016/j.ijpharm.2024.124058, PMID 38552754.

60. Pereira BC, Isreb A, Isreb M, Forbes RT, Oga EF, Alhnan MA. Additive manufacturing of a point of care polypill: fabrication of concept capsules of complex geometry with bespoke release against cardiovascular disease. Adv Healthc Mater. 2020;9(13):e2000236. doi: 10.1002/adhm.202000236, PMID 32510859.

61. Algahtani MS, Mohammed AA, Ahmad J, Saleh E. Development of a 3D printed coating shell to control the drug release of encapsulated immediate release tablets. Polymers (Basel). 2020 Jun 22;12(6):1395. doi: 10.3390/polym12061395, PMID 32580349, PMCID PMC7362262.

62. Xu X, Zhao J, Wang M, Wang L, Yang J. Author correction: 3D printed polyvinyl alcohol tablets with multiple release profiles. Sci RepSci Rep. 2020;10(1):2394. doi: 10.1038/s41598-020-59303-w, PMID 32024930.

63. Potpara Z. The role of 3D printing in the development of dosage forms with tailored drug release. Farmacia. 2024;72(6):1251-60. doi: 10.31925/farmacia.2024.6.3.

Published

01-08-2025

How to Cite

JOSHI, PUNEET, et al. “3D PRINTING IN PHARMACEUTICALS: TRANSFORMING DRUG FORMULATION AND PERSONALIZED MEDICINE”. International Journal of Pharmacy and Pharmaceutical Sciences, vol. 17, no. 8, Aug. 2025, pp. 1-7, doi:10.22159/ijpps.2025v17i8.54888.

Issue

Section

Review Article(s)

Similar Articles

<< < 9 10 11 12 13 > >> 

You may also start an advanced similarity search for this article.