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3D printing of high drug loaded dosage forms using thermoplastic polyurethanes

Glenn Verstraete (UGent) , Aseel Samaro (UGent) , Wouter Grymonpré (UGent) , Valérie Vanhoorne (UGent) , Bernd Van Snick (UGent) , Matthieu Boone (UGent) , Tom Hellemans (UGent) , Luc Van Hoorebeke (UGent) , Jean Paul Remon (UGent) and Chris Vervaet (UGent)
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Abstract
It was the aim of this study to develop high drug loaded (> 30%, w/w), thermoplastic polyurethane (TPU)-based dosage forms via fused deposition modelling (FDM). Model drugs with different particle size and aqueous solubility were pre-processed in combination with diverse TPU grades via hot melt extrusion (HME) into filaments with a diameter of 1.75 +/- 0.05 mm. Subsequently, TPU-based filaments which featured acceptable quality attributes (i.e. consistent filament diameter, smooth surface morphology and good mechanical properties) were printed into tablets. The sustained release potential of the 3D printed dosage forms was tested in vitro. Moreover, the impact of printing parameters on the in vitro drug release was investigated. TPU-based filaments could be loaded with 60% (w/w) fine drug powder without observing severe shark skinning or inconsistent filament diameter. During 3D printing experiments, HME filaments based on hard TPU grades were successfully converted into personalized dosage forms containing a high concentration of crystalline drug (up to 60%, w/w). In vitro release kinetics were mainly affected by the matrix composition and tablet infill degree. Therefore, this study clearly demonstrated that TPU-based FDM feedstock material offers a lot of formulation freedom for the development of personalized dosage forms.
Keywords
Personalized medicine, 3D printing, Fused deposition modelling, Thermoplastic polyurethanes, Sustained release, High drug load, HOT-MELT EXTRUSION, FUSED DEPOSITION, RELEASE CHARACTERISTICS, TABLETS, FABRICATION, DELIVERY, MATRICES, DEVICES, FORMULATION, IMMEDIATE

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Chicago
Verstraete, Glenn, Aseel Samaro, Wouter Grymonpré, Valérie Vanhoorne, Bernd Van Snick, Matthieu Boone, Tom Hellemans, Luc Van Hoorebeke, Jean Paul Remon, and Chris Vervaet. 2018. “3D Printing of High Drug Loaded Dosage Forms Using Thermoplastic Polyurethanes.” International Journal of Pharmaceutics 536 (1): 318–325.
APA
Verstraete, Glenn, Samaro, A., Grymonpré, W., Vanhoorne, V., Van Snick, B., Boone, M., Hellemans, T., et al. (2018). 3D printing of high drug loaded dosage forms using thermoplastic polyurethanes. INTERNATIONAL JOURNAL OF PHARMACEUTICS, 536(1), 318–325.
Vancouver
1.
Verstraete G, Samaro A, Grymonpré W, Vanhoorne V, Van Snick B, Boone M, et al. 3D printing of high drug loaded dosage forms using thermoplastic polyurethanes. INTERNATIONAL JOURNAL OF PHARMACEUTICS. 2018;536(1):318–25.
MLA
Verstraete, Glenn, Aseel Samaro, Wouter Grymonpré, et al. “3D Printing of High Drug Loaded Dosage Forms Using Thermoplastic Polyurethanes.” INTERNATIONAL JOURNAL OF PHARMACEUTICS 536.1 (2018): 318–325. Print.
@article{8561414,
  abstract     = {It was the aim of this study to develop high drug loaded (> 30%, w/w), thermoplastic polyurethane (TPU)-based dosage forms via fused deposition modelling (FDM). Model drugs with different particle size and aqueous solubility were pre-processed in combination with diverse TPU grades via hot melt extrusion (HME) into filaments with a diameter of 1.75 +/- 0.05 mm. Subsequently, TPU-based filaments which featured acceptable quality attributes (i.e. consistent filament diameter, smooth surface morphology and good mechanical properties) were printed into tablets. The sustained release potential of the 3D printed dosage forms was tested in vitro. Moreover, the impact of printing parameters on the in vitro drug release was investigated. TPU-based filaments could be loaded with 60% (w/w) fine drug powder without observing severe shark skinning or inconsistent filament diameter. During 3D printing experiments, HME filaments based on hard TPU grades were successfully converted into personalized dosage forms containing a high concentration of crystalline drug (up to 60%, w/w). In vitro release kinetics were mainly affected by the matrix composition and tablet infill degree. Therefore, this study clearly demonstrated that TPU-based FDM feedstock material offers a lot of formulation freedom for the development of personalized dosage forms.},
  author       = {Verstraete, Glenn and Samaro, Aseel and Grymonpré, Wouter and Vanhoorne, Valérie and Van Snick, Bernd and Boone, Matthieu and Hellemans, Tom and Van Hoorebeke, Luc and Remon, Jean Paul and Vervaet, Chris},
  issn         = {0378-5173},
  journal      = {INTERNATIONAL JOURNAL OF PHARMACEUTICS},
  keywords     = {Personalized medicine,3D printing,Fused deposition modelling,Thermoplastic polyurethanes,Sustained release,High drug load,HOT-MELT EXTRUSION,FUSED DEPOSITION,RELEASE CHARACTERISTICS,TABLETS,FABRICATION,DELIVERY,MATRICES,DEVICES,FORMULATION,IMMEDIATE},
  language     = {eng},
  number       = {1},
  pages        = {318--325},
  title        = {3D printing of high drug loaded dosage forms using thermoplastic polyurethanes},
  url          = {http://dx.doi.org/10.1016/j.ijpharm.2017.12.002},
  volume       = {536},
  year         = {2018},
}

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