Innovations in Chewable Formulations: The Novelty and Applications of 3D Printing in Drug Product Design

Abstract

Since their introduction, chewable dosage forms have gained traction due to their ability to facilitate swallowing, especially in paediatric, geriatric and dysphagia patients. Their benefits stretch beyond human use to also include veterinary applications, improving administration and palatability in different animal species. Despite their advantages, current chewable formulations do not account for individualised dosing and palatability preferences. In light of this, three-dimensional (3D) printing, and in particular the semi-solid extrusion technology, has been suggested as a novel manufacturing method for producing customised chewable dosage forms. This advanced approach offers flexibility for selecting patient-specific doses, excipients, and organoleptic properties, which are critical for ensuring efficacy, safety and adherence to the treatment. This review provides an overview of the latest advancements in chewable dosage forms for human and veterinary use, highlighting the motivations behind their use and covering formulation considerations, as well as regulatory aspects.

Tabletized Nanomedicine: From the Current Scenario to Developing Future Medicine

“…Such tablets are developed through a direct compression method, aiming for swift dissolution within the oral cavity. This unique ODT design allows ease administration without the need for water, thereby enhancing pediatric and geriatric patient’s compliance . In another work, a pediatric visual preference survey of 3D-printed tablets was conducted.…”

Inkjet Printing of Pharmaceuticals

“…ODTs are particularly advantageous for patients who have difficulty swallowing traditional tablets, offering a more convenient and patient‐friendly mode of drug administration. [ 116 ] The biocompatibility of foams ensures their safety for use in drug delivery applications. Their ability to promote cell adhesion and proliferation also makes them a promising substrate for tissue engineering and regenerative medicine applications.…”

3D Printing of Dietary Products for the Management of Inborn Errors of Intermediary Metabolism in Pediatric Populations

“…Additionally, as they are chewed and broken down into smaller pieces, they can be produced in sizes larger than conventional tablets, allowing higher amounts of drugs to be loaded into them [ 118 ]. Chewable formulations share some advantages with conventional tablets, including portability and long-term stability [ 119 ]. Utilizing pharmaceutical excipients, these formulations address sensory characteristics with coloring agents, sweeteners, flavors, and design aesthetics, creating shapes that are appealing to children [ 118 ].…”

“…Comparatively, tableting machines, the traditional counterparts, also come with considerable costs. Moreover, the raw materials used in 3D printing—similar to those used in conventional tablet manufacturing—do not incur additional expenses [ 89 , 119 , 156 ]. Furthermore, the majority of developed formulations generally eliminate the need for extra post-printing steps, thus not incurring added costs.…”

“…Challenges arise in conducting quality control tests, especially for chewable tablets, a promising form for pediatric patients affected by IEiM disorders, due to the lack of specific monographs in major pharmacopeias [ 119 ]. Although FDA recommendations exist [ 158 ], conducting these conventional QC tests can be impractical for on-demand production at clinical trial sites using 3D printing due to their destructive, laborious, and costly nature.…”