Continuous manufacturing of 3D-printed chewable pediatric gummies by coupling hot melt extrusion with direct extrusion additive manufacturing

Background 3D printing has been extensively explored as a novel approach to fabricating customized pharmaceuticals due to its adaptability. In this study, a continuous 3D (3-dimensional) printing platform was developed for the fabrication of chewable, gummy-like pediatric tablets by coupling Hot Melt Extrusion and Direct Extrusion Printing.Research design and methods The effects of polymer composition, super disintegrants, and infill density on extrusion, printability, and structural integrity were systematically evaluated. Rheological analysis revealed that optimized inks exhibited stable shear-thinning behavior as low as 1.0x105 to 1.0x106 mPa/s with increasing shear rates, ensuring smooth extrusion and excellent layer adhesion. In vitro dissolution studies demonstrated that tablet geometry, infill density, and ink composition could be tailored to achieve immediate drug release.Results 30% and 50% infill structures provided reduced compressive resistance suitable for soft, chewable tablets and resulted in nearly 90% drug release within 30 min. Sensory assessment confirmed effective taste masking via hydrogen-bonding interactions, and optimized sweetener – flavor ratios ensured palatability.Conclusions 3D printing enabled the production of pediatric-friendly, chewable dosage forms with tailored mechanical, dissolution, and sensory properties, supporting personalized medicine and enhanced patient compliance.