3D printing of novel drug delivery devices using fused deposition modelling

3D printers operating on Fused Deposition Modelling (FDM) technology build parts layer-on-layer by heating thermoplastic material to a molten state and extruding it according to computer-controlled pathways. Originally developed for the rapid prototyping of models in engineering design, in the last decade this technology has been adopted for short manufacturing runs through to domestic 3D printers. An exciting development of the FDM process is the ability to print multiple polymeric materials within the same part, opening the potential for more complex devices to be produced. In this project, we propose to evaluate the potential of FDM 3D printing as a manufacturing tool for polymeric drug delivery devices that could ultimately be tailored and personalised for smaller patient groups or individuals. There are a number of key areas that form the basis of this investigation: (i)Materials: identification of suitable polymers that are compatible with the FDM process and delivery of a range of active pharmaceutical ingredients (APIs); (ii)Processing: incorporation of APIs into thermoplastics and the modification of FDM equipment to work with different polymer and API blends; (iii)Drug Delivery Device Design: devices using controlled placement of API loaded-non-API regions and different polymers to give customisable controlled release profiles, pulsatile release and combination therapies from a single dosage form. This includes implantable drug delivery devices that can be manufactured with personalised release rates of drugs for cancer treatment and other clinical indications. The project, based in the School of Pharmacy but may use other facilities/equipment, will offer the student a unique opportunity to be involved in a cross-disciplinary project and to develop key skills across a range of engineering and scientific disciplines.