Evolution, integration, and challenges of 3D printing in pharmaceutical applications: A comprehensive review

Three-dimensional (3D) printing involves fabricating objects from digital designs by sequentially layering materials along the X, Y, and Z axes. Although this technology has existed since the 1960s, its adoption in the pharmaceutical industry remains limited. This review examines the evolution of 3D printing and its emerging significance in pharmaceuticals. The technique offers numerous advantages, such as product customization, cost-effectiveness, and efficient material usage. Several methods—such as inkjet printing, extrusion printing, and beam-based printing—are employed, utilizing materials ranging from lactose and hydroxypropyl methylcellulose to bioinks like chitosan and hyaluronic acid. Among these techniques, fused deposition modelling (FDM) is particularly noteworthy for its versatility in both biodegradable and non-biodegradable applications. Advances in 3D printing have paved the way for innovative pharmaceutical uses, including the production of complex oral dosage forms, drug delivery systems, and medical devices such as prosthetics. More recent breakthroughs have extended into bioprinting, organ-on-a-chip technologies, and robotics. However, several challenges hinder broader adoption, including limited compatibility with thermosensitive materials, difficulties in scaling production, and maintaining quality control. Additionally, the lack of standardized regulatory and ethical frameworks for clinical approval complicates progress. This review explores the key 3D printing techniques, materials, and trends relevant to pharmaceuticals, while addressing resource constraints, intellectual property issues, and regulatory hurdles. It concludes by identifying future directions for research and development, emphasizing the need to optimize these technologies for widespread pharmaceutical applications.