PhD Scientific Days 2025

Poster Session I. - F: Pharmaceutical Sciences and Health Technologies

Integrating Hot Melt Extrusion and 3D Printing in Pharmaceutical Manufacturing: Formulation Strategies and Future Prospects

Name of the presenter

Orekhova Xeniya

Institute/workplace of the presenter

Semmelweis University – Department of Pharmaceutics

Authors

Xeniya Orekhova¹

1: Semmelweis University – Department of Pharmaceutics

Text of the abstract

Introduction
Modern pharmaceutical excipients are expected to exhibit enhanced functionality, as the single-step formulation strategies require high-performance compounds. One of the possible ways to enhance these pharmaceutical substances is co-processing. This technique involves physical homogenization without significant chemical change, yet it results in more favorable physicochemical properties of the final product.
Aims
The aim of this research was to analyze the current opportunities of integrating hot melt extrusion and fused deposition modeling in pharmaceutical manufacturing. The particular focus was on the formulation strategies, active ingredients, excipient considerations and potential for industrial scale implementation. In addition to that, the objective was to optimize HME process parameters to form 3D-printable filaments. HME is particularly advantageous due to its ability to improve solubility of poorly water-soluble drugs and stability of amorphous solid dispersions facilitating sustained drug release.
Methods
Traditional pharmaceutical excipients were screened (e.g.: isomalt, polyethylene glycols) and the optimal candidates were hot-melt extruded with Felfil Evo (Felfil, Italy). During the process, the following parameters were examined: Rotation of the screw: 1-9 RPM, chamber temperature: 80-250 °C, cooling fan performance: 0-100%. To assess solubility enhancer effect, model active ingredient was also co-processed and filaments with a diameter of 1.75 mm were formulated and directly printed via Creality Ender 3 printer (Creality, China). The dissolution profile was tracked in biorelevant circumstances (pH=1.2; 6.8).
Results
During my study, I have optimized the HME process in case of versatile excipients and ratios. The compounds with desirable printability were further co-processed with active ingredient, and the dissolution profile of the products were recorded. This innovative method is capable of enhancing the processability and bioavailability of poorly soluble drugs.
Conclusion
Integrating 3D printing into pharmaceutical manufacturing, with a specific focus on co-processing excipients is key to advancing personalized medicine. The importance of co-processing excipients within this context lies in the potential to tailor dosage forms to individual patient needs, optimizing drug delivery and therapeutic outcomes.