Development, Fabrication and Application of a Sectioned 3D-Printed Human Nasal Cavity Model for In Vitro Nasal Spray Deposition Studies

In vitro models of the human nasal cavity are crucial for understanding the deposition dynamics of nasally administered drugs. Three-dimensional (3D) printing offers a powerful method for creating patient-specific, anatomically precise models for such experimental purposes. Background/Objectives: This study details the complete workflow for the development, design, and fabrication of a sectioned nasal cavity model intended for droplet deposition analysis of nasal sprays. Methods: A digital nasal cavity model was derived from medical imaging data and optimized for computer-aided design (CAD) operations. It was segmented into five therapeutically relevant regions: nasal vestibule, olfactory area, middle and upper turbinates, lower turbinate, and nasopharynx. Sections were 3D-printed in polypropylene for chemical compatibility, and a carbon fiber-reinforced fixation frame ensured precise alignment and airtight assembly. Results: Functional validation confirmed the model’s functional relevance through comparative deposition studies using automated actuation and high-performance liquid chromatography (HPLC) based regional quantification. Two devices with distinct spray characteristics (characterized separately by laser diffraction, plume geometry, and spray pattern imaging) were tested under varied administration conditions. The study demonstrated the model’s ability to discriminate between products, establishing a solid foundation for future investigations incorporating additional variables. Conclusions: Overall, the developed methodology provides a cost-effective and replicable platform for producing anatomically accurate, sectioned nasal cavity models. The newly developed in vitro system is well suited for detailed, region-specific analysis of nasal spray deposition, offering a valuable tool for pharmaceutical research and development.