Evaluation of the Applicability of a 3D-Printed Inert Minitablet Core as a Carrier for Modified-Release Drug Delivery System

Background/Objectives: The growing demand for personalised, patient-centric drug delivery systems has driven innovation in pharmaceutical manufacturing, particularly in multi-unit particulate systems (MUPS). Methods: In this study, inert cores with tailor-made geometry for multi-particulate formulations were fabricated with high-resolution stereolithography (SLA) 3D printing. By a printable photopolymer resin, dimensionally accurate and mechanically robust starter cores were produced. The additively manufactured inert subunits were drug-layered with ibuprofen sodium using a fluidised bed process. Then, a controlled-release film coating of Eudragit RS 30D was applied with varying coating thicknesses. The initial 3D-printed subunits, together with the drug-layered and finally film-coated microparticles, were characterised by image analysis, Raman microspectroscopic measurements, and official methods of the European Pharmacopoeia. Results: The combined approach of 3D printing and traditional pharmaceutical processing proved highly effective. The 3D-printed cores demonstrated both flexibility in design and consistency in performance. Conclusions: These findings highlight the feasibility of using 3D printing to produce patient-specific, functional cores in multi-particulate systems that can be easily modified according to the patient’s needs. The fabricated minitablets can be used as alternatives to widely used inert cores. Integrating additive manufacturing with conventional coating techniques offers promising new avenues for developing next-generation, personalised drug delivery solutions.