Electronic Theses and Dissertations

Date of Award

1-1-2024

Document Type

Dissertation

Degree Name

Ph.D. in Pharmaceutical Sciences

First Advisor

Michael A. Repka

Second Advisor

Eman Ashour

Third Advisor

Samir Ross

Relational Format

dissertation/thesis

Abstract

This dissertation explores the integration of Hot Melt Extrusion (HME) and Fused Deposition Modeling (FDM) 3D printing as a novel continuous manufacturing process for pharmaceutical dosage forms. Emphasizing the creation of personalized and complex drug delivery systems, this work highlights the potential of 3D printing technology in revolutionizing pharmaceutical manufacturing by offering customized dosage, precise API distribution, and efficient production with minimal waste. The first chapter delves into the fabrication of bilayer tablets utilizing HME in conjunction with dual-nozzle FDM 3D printing, examining the mechanical properties of HME filaments and the printing quality through a novel 3D printed tablet retention rate method. Furthermore, the drug dissolution behavior of the bilayer tablets is analyzed to evaluate their performance. In the second chapter, various extended-release tablet models are designed and printed, with a comparative analysis of the dissolution profiles of different polymers, showcasing the versatility in tailoring drug release rates. The third chapter demonstrates the successful printing of suppository shells using diverse materials, underscoring the feasibility of employing HME and 3D printing for suppository development. Overall, this research substantiates the synergy between HME and 3D printing as an efficient, economical, and innovative approach for producing personalized and complex dosage forms, marking a significant advancement in pharmaceutical manufacturing technologies.

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