On demand manufacturing of patient-specific oral doses provides significant advantages to patients and healthcare staff. Several 3D printing (3DP) technologies have been proposed as a potential digital alternative to conventional manufacturing of oral tablets. For additive manufacturing approach to be successful for on-demand preparation, a facile process with minimal preparation steps and training requirements is needed. A novel hybrid approach to the 3D printing process is demonstrated here based on combined solvent and heating elements/factors/aspects to facilitate extrusion. The system employed a moderate elevated temperature range of (65-100 o C), a brief drying period, and a simple set-up. In this approach, a compact powder cylinder is used as a pharmaceutical ink to be extruded in a temperaturecontrolled metal syringe. The process proved compatible with hygroscopic polymers [Poly(vinyl alcohol (PVA) and poly(vinyl pyridine) (PVP)] and a number of pharmaceutical fillers (lactose, sorbitol and mannitol). The fabricated tablets demonstrated compendial acceptable weight and content uniformity as well as mechanical resistance. In vitro drug release of theophylline from 3D printed tablets was dependant on the nature of the polymer and its molecular weight. This reported approach offers significant advantages compared to other 3DP technologies: simplification of pre-product, the use of a moderate temperature range, a minimal drying period, and avoiding the use of mechanically complicated direct extruder machinery. In the future, we envisage the use of this low-cost and facile approach to fabricate small batches of bespoke tablets.
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