Three-dimensional (3D) printing is revolutionising how we envision manufacturing in the pharmaceutical field. Here, we report for the first time the use of Direct Powder Extrusion 3D printing: a novel, single-step printing process Single-screw direct powder extrusion 3D printing has been successfully used for the first time tofor the production of prepare printlets (3D printed tablets) directly from powdered materials. This newovel 3D printing technology has allowedwas used to prepare amorphous solid dispersions of itraconazole using the preparation amorphous solid dispersion of itraconazole in an amorphous solid dispersion directly from powdered materials using with four different grades of hydroxypropylcellulose (HPC-UL, SSL, SL and L). All of the printlets showed good mechanical and physical characteristics and no drug degradation. The printlets showed sustained drug release characteristics, withs and drug concentrations higher than the solubility of the drug itself. The printlets prepared with the ultra-low molecular grade (HPC-UL) showed faster drug release compared withthan the other HPC grades, attributed to the fact that itraconazole wasis found in a higher percentage a higher percentage as an amorphous solid dispersion. This work also demonstrates the potential of thisat this innovate technology tocan overcome one of the major disadvantages of fused deposition modelling (FDM) 3D printing by avoiding the need for preparation of filaments by hot melt extrusion (HME). This novel single-step new technology could revolutioniisze the preparation of amorphous solid dispersions as final formulations and it may be especially suited for preclinical studies, where the quantity of drugs is limited and without the need of using traditional HME.

The aim of this work was to explore the feasibility of using selective laser sintering (SLS) 3D printing (3DP) to fabricate orodispersable printlets (ODPs) containing ondansetron. Ondansetron was first incorporated into drug-cyclodextrin complexes and then combined with the filler mannitol. Two 3D printed formulations with different levels of mannitol were prepared and tested, and a commercial ondansetron orally disintegrating tablet (ODT) product (Vonau® Flash) was also investigated for comparison. Both 3D printed formulations disintegrated at ~15 s and released more than 90% of the drug within 5 min independent of the mannitol content; these results were comparable to those obtained with the commercial product. This work demonstrates the potential of SLS 3DP to fabricate orodispersible printlets with characteristics similar to a commercial ODT, but with the added benefit of using a manufacturing technology able to prepare medicines individualized to the patient.