Recent Advances in 3D Printing of Pharmaceutical Dosage Forms

A special issue of Pharmaceutics (ISSN 1999-4923). This special issue belongs to the section "Physical Pharmacy and Formulation".

Deadline for manuscript submissions: 31 December 2025 | Viewed by 1229

Special Issue Editors


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Guest Editor
Department of Pharmacy, Faculty of Medicine Novi Sad, University of Novi Sad, 21000 Novi Sad, Serbia
Interests: HPLC; LC-MS; UV-VIS spectroscopy; drug formulation development and optimisation; biorelevant dissolution; 3D printing; drug permeability enhancement research (GIT, blood-brain and placental barrier)

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Guest Editor
Department of Pharmacy, Faculty of Medicine, University of Novi Sad, Hajduk Veljkova 3, 21000 Novi Sad, Serbia
Interests: emulsions; surfactants; polymers; rheology
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Special Issue Information

Dear Colleagues,

We are pleased to invite contributions to this Special Issue titled “Recent Advances in 3D Printing of Pharmaceutical Dosage Forms”, which seeks original research articles and review papers. Three-dimensional printing has brought significant changes in the development of pharmaceutical dosage forms, offering new opportunities and challenges. This Special Issue aims to highlight the application of 3D printing in pharmacy, exploring both its potential and limitations. We welcome papers focusing on the functionality of conventional and novel pharmaceutical excipients in the 3D printing of medicines, the influence of 3D printing process parameters on the quality and biological effects of the resulting drug products, as well as research on related technologies such as hot melt extrusion. Additionally, contributions exploring other potential applications of 3D printing in pharmacy, beyond drug printing, are of great interest. This includes research on the printing of new devices or components for the manufacturing, production, and characterization of pharmaceutical dosage forms.

Prof. Dr. Mladena Lalic-Popovic
Prof. Dr. Veljko Krstonošić
Guest Editors

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Keywords

  • drug delivery
  • 3D printing
  • additive manufacturing
  • personalized medicine
  • pharmaceutical excipients
  • polymers
  • biopolymers
  • hot melt extrusion (HME)
  • fused deposition modeling (FDM)
  • selective laser sintering (SLS)

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Published Papers (1 paper)

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Research

27 pages, 4957 KB  
Article
Mould-Free Microneedles in a Single Step: 3D Printing with Photopolymer Resins for Transdermal Delivery
by Rutuja N. Meshram and Dimitrios A. Lamprou
Pharmaceutics 2025, 17(11), 1498; https://doi.org/10.3390/pharmaceutics17111498 - 19 Nov 2025
Viewed by 938
Abstract
Background: Digital light processing (DLP) 3D printing has emerged as a rapid alternative to labour-intensive micro-moulding for producing microneedle (MN) arrays, yet its use in biodegradable, dissolving MNs has been limited by proprietary, non-degradable resins. Methods: The current study proposed an innovative, biocompatible [...] Read more.
Background: Digital light processing (DLP) 3D printing has emerged as a rapid alternative to labour-intensive micro-moulding for producing microneedle (MN) arrays, yet its use in biodegradable, dissolving MNs has been limited by proprietary, non-degradable resins. Methods: The current study proposed an innovative, biocompatible PEGDA–vinyl-pyrrolidone photo-resin with lithium phenyl(2,4,6-trimethylbenzoyl) phosphinate initiator, which systematically optimises its rheology and photo-reactivity for DLP printing. Resin formulations were evaluated through viscosity profiling, cure kinetics, FTIR, and 1H NMR, and MN arrays were printed using a desktop DLP platform and characterised by optical microscopy, mechanical testing, thermal analysis, and dissolution studies. Results: A 40% PEGDA up-to 100% VP blend with 0.4% initiator was identified as providing rapid photopolymerisation, low shrinkage and complete vinyl conversion. Using a desktop DLP platform, 6 × 6 MN patches were printed in a single step without moulds and analysed by optical and scanning electron microscopy. The printed MNs reproduced CAD dimensions with <3% deviation, achieving a height of 1.40 ± 0.02 mm and a base thickness of 1.00 ± 0.01 mm, and showed a tip radius consistent with sharp penetration. Compression testing measured an array force of 32 N, corresponding to ~0.9 N per needle, exceeding the 0.2 N threshold for skin insertion. FTIR and 1H NMR confirmed near-quantitative crosslinking, thermogravimetric and differential scanning calorimetry indicated stability at ambient conditions, and dissolution studies showed complete needle dissolution. Conclusions: An optimised PEGDA/VP resin yields geometrically precise, mechanically robust dissolving MNs in a single step, addressing the limitations of micro-moulding and paving the way for customisable, on-demand transdermal delivery of active molecules and biologics. Full article
(This article belongs to the Special Issue Recent Advances in 3D Printing of Pharmaceutical Dosage Forms)
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