Abstract

3D PRINTING TECHNOLOGIES AND ARTIFICIAL INTELLIGENCE IN PERSONALIZED SOLID ORAL DOSAGE FORM DESIGN: CURRENT PROGRESS AND FUTURE PERSPECTIVES

Imran Fareeth A. M., Vignesh M.*, Dr. Selvaraju K., Alex Pandiyan J., Dhanush Narayanan R.

Abstract

Three-dimensional (3D) printing is transforming oral drug delivery by enabling the precise fabrication of solid dosage forms with patient-specific doses, geometries, and release profiles, thus supporting the paradigm of personalized medicine. Unlike conventional batch manufacturing, additive manufacturing techniques such as fused deposition modeling, binder jetting, and allow rapid, on-demand production of complex tablets and polypills, including multi-layer and compartmentalized structures that can combine several active pharmaceutical ingredients (APIs) with distinct release kinetics in a single unit. This flexibility is particularly valuable for populations requiring fine dose titration or simplified regimens, such as paediatric, geriatric, and polymorbid patients, and for chronic or complex diseases like epilepsy, diabetes, and cardiovascular disorders Artificial intelligence (AI) significantly amplifies this potential by learning quantitative relationships between formulation composition, printing parameters, and in vitro performance, then using these models to automatically propose tablet architectures that meet predefined therapeutic or pharmacokinetic targets.AI-driven tools can predict excipient–drug compatibility, optimize printing conditions, and implement real-time monitoring and adaptive control, thereby reducing trial-and-error, enhancing process robustness, and enabling consistent quality in both centralized and point-of-care manufacturing settings. Despite these advantages, widespread adoption is constrained by challenges in standardizing materials and printers, ensuring long- term stability and reproducibility, and the absence of harmonized regulatory frameworks tailored to decentralized, small-batch production. Continuing integration of Quality by Design principles, digital quality control, and AI-based decision support is essential to translate AI-guided 3D printing of oral dosage forms from experimental platforms into routine, clinically integrated personalized therapy.

Keywords: 3D printing, Personalized medicine, Artificial intelligence, Fused Deposition Modelling.