Material Considerations for Fused-Filament Fabrication of Solid Dosage Forms

Evert Fuenmayor, Martin Forde, Andrew V. Healy, Declan M. Devine, John G. Lyons, Christopher McConville, Ian Major

Research output: Contribution to journalArticlepeer-review

51 Citations (Scopus)
201 Downloads (Pure)


Material choice is a fundamental consideration when it comes to designing a solid dosage form. The matrix material will ultimately determine the rate of drug release since the physical properties (solubility, viscosity, and more) of the material control both fluid ingress and disintegration of the dosage form. The bulk properties (powder flow, concentration, and more) of the material should also be considered since these properties will influence the ability of the material to be successfully manufactured. Furthermore, there is a limited number of approved materials for the production of solid dosage forms. The present study details the complications that can arise when adopting pharmaceutical grade polymers for fused-filament fabrication in the production of oral tablets. The paper also presents ways to overcome each issue. Fused-filament fabrication is a hot-melt extrusion-based 3D printing process. The paper describes the problems encountered in fused-filament fabrication with Kollidon® VA64, which is a material that has previously been utilized in direct compression and hot-melt extrusion processes. Formulation and melt-blending strategies were employed to increase the printability of the material. The paper defines for the first time the essential parameter profile required for successful 3D printing and lists several pre-screening tools that should be employed to guide future material formulation for the fused-filament fabrication of solid dosage forms.

Original languageEnglish
Issue number2
Publication statusPublished - 2 Apr 2018


  • 3D printing
  • fused-filament fabrication
  • additive manufacturing
  • hot-melt extrusion
  • formulation
  • melt-blending
  • solid dosage forms
  • tablets


Dive into the research topics of 'Material Considerations for Fused-Filament Fabrication of Solid Dosage Forms'. Together they form a unique fingerprint.

Cite this