FDM 3D Printing as an Innovative Technology for Fabricating Personalized Topical Drug Delivery Systems

Systems A. Goyanes, U. Det-Amornrat, J. Wang, A. Basit, S. Gaisford University College London Purpose 3D printing (3DP) technology offers the potential to revolutionize the future of pharmaceutical manufacturing, with the ability to fabricate structures of precise geometries from a 3D model. In fused-deposition modeling (FDM) 3D printing a polymer filament is heated and extruded through a small tip and solidified on a build plate to create the final object. 3D scanning technology can be used to obtain 3D models adapted to the morphology of an individual. To our knowledge, there has been no demonstration on the use of 3D scanning and FDM printing to manufacture personalized-shape topical drug delivery systems. Here, we evaluated the feasibility of printing anti-acne flexible patches/masks personalised to the anatomy of an individual by 3D scanning and FDM 3DP. Methods Commercially produced Flex EcoPLA (FPLA) and polycaprolactone (PCL) filaments were loaded with salicylic acid (theoretical loading 2% w/w) by hot melt extrusion (HME). To do so, the polymers were dissolved in an appropriate organic solvent and mixed with a solution of salicylic acid. The solution was evaporated and the remaining mixture was cut in to small parts before extruding using a Filabot hot melt extruder. Devices were fabricated from the drug-loaded filaments with a MakerBot Replicator 2X Desktop 3D printer. The 3D model of a nose used to print (adapted to the shape and size of an individual) was obtained by 3D scanning (Sense 3D scanner, 3D systems, USA). Drug diffusion tests from the 3D printed flat patches were conducted using Franz cells with cellulose nitrate membranes.