Development of ibuprofen tablet with polyethylene oxide using fused deposition modeling 3D-printing coupled with hot-melt extrusion

Ibuprofen is known to plasticize several polymers used in hot-melt extrusion, and it is considered challenging to achieve immediate release for ibuprofen using fused deposition modeling. Therefore, this study aimed to print ibuprofen tablets with a focus on achieving rapid release. Polyethylene oxide (Polyox WSR N80) was used as the main matrix to form the ibuprofen filament, because of its water-soluble properties and ability to manifest suitable mechanical properties, even with high drug loading (40% w/w). Several release modifiers, such as Kollidon VA64, Kollidon 12PF, Kollicoat IR, Kollidon CL, and mannitol, were added separately to the formula-tion, following which their effects on enhancing the drug release rate were investigated. Their effects on the mechanical properties of the filaments have also been assessed in this study. It was demonstrated that adding soluble Kollidon grades, such as Kollidon VA64 and Kollidon 12PF, enhanced the drug release rate. In addition, the tablet design with a high surface-to-mass ratio was beneficial for increasing the drug release rate. However, incorporation of the release modifiers discussed above decreased the flexural modulus of the filament. Addi-tionally, it is important to tailor the printing parameters by considering the properties of the filament, to acquire good quality printlets. The tablet consisting of 30% ibuprofen and 20% Kollidon VA64 at the highest dose used in this study (84 mg) released 80% of the drug, in approximately 90 min. To further increase the release rate and drug dose, other additives, such as viscosity-increasing agents and reinforcing additives, can be explored. This study shows the potential of fabricating ibuprofen tablets with rapid release characteristics using Polyox WSR N80, via fused deposition modeling 3D-printing.