Customization of Drug Delivery using 3D Printing Technologies: A Material Driven Review

Advanced software, tools, and manufacturing technologies have significantly expanded the potential of three-dimensional (3D) printing in pharmaceutical sciences. The application of 3D printing enables pharmaceutical scientists to develop individualized, patient-centred drug delivery systems that move beyond the traditional “one-size-fits-all” approach. Additive manufacturing offers superior flexibility in customizing dosage form geometry, internal structure, and drug distribution, allowing precise control over drug release profiles and the incorporation of multiple therapeutics within a single formulation. These advantages contribute to improved patient compliance and enhanced clinical outcomes. This review provides a comprehensive overview of 3D printing technologies applied to drug delivery systems, covering fundamental principles, printable materials, and recent advancements across diverse pharmaceutical applications. The manuscript discusses major printing techniques, including fused deposition modelling, stereolithography, inkjet printing, selective laser sintering, and semi-solid extrusion, along with their pharmaceutical relevance. Various materials such as biodegradable and non-biodegradable polymers, hydrogels, and inorganic composites are highlighted due to their biocompatibility and processing suitability. Emphasis is placed on the role of digital modelling, simulation, and patient-specific data in designing personalized dosage forms to achieve optimal therapeutic outcomes. Additionally, the review addresses the characterization of 3D-printed pharmaceuticals and examines existing regulatory, ethical, and technical challenges [60,69,70]. Finally, future perspective’s including 4D printing, artificial intelligence–assisted design, and sustainable biomaterials are discussed [57,63]. Overall, 3D printing holds substantial potential to revolutionize personalized medicine by bridging the gap between digital manufacturing technologies and clinical practice.