Three-dimensional printing personalized acetaminophen sustained-release tablets using hot melt extrusion

The purpose of this study was to prepare bespoke sustained-release tablets in one step using hot melt extrusion 3D printing technology. Acetaminophen-loaded tablets were produced by processing a physical mixture of the active pharmaceutical ingredient (35%) and copovidone with a plasticizer (Poloxamer 407) through hot melt extrusion (HME). Computer software was used to design a cylinder-shaped tablet, the strength and release rate of the tablet were controlled by changing its structure to achieve individual administration. Three different strengths of acetaminophen sustained-release tablets (350 mg, 500 mg, and 650 mg) were successfully printed, and they demonstrated excellent mechanical properties and acceptable in-batch variability. The physical form of the drugs and their integrity following fused deposition modelling 3D printing were assessed using scanning electron microscopy (SEM), x-ray powder diffractometry (XRPD), thermal analysis, and high-performance liquid chromatography (HPLC). The in vitro release of the different strengths of tablets was more than 85% in 3 h, and the release pattern was similar to that of that the commercially available formulation. These results show that 3D printing technology can prepare sustained-release drug preparations conveniently, quickly, and flexibly; simplify the traditional preparation process; ensure the safety and effectiveness of 3D printing drugs; and support the potential of HME 3D printing technology in the pharmaceutical industry.