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Purpose <p>Personalized oral drug delivery requires an advanced manufacturing platform capable of programmable geometry and personalized release kinetics, especially for drugs that have an extended gastric retention period. This study developed and validated a multicompartment gastroretentive floating tablet of ondansetron hydrochloride dihydrate (OHD) using FDM 3D-printing and investigated whether geometrical modulation of compartment architecture could be exploited to achieve programmable biphasic drug release.</p> Methods <p>Polyvinyl alcohol (PVA) filament was chosen after screening of printability, mechanical strength, buoyancy, and release suitability. 3D-printed tablets (F1-F4) were designed via AutoCAD with varied wall-thicknesses and orifices structures and printed through optimized FDM parameters. During printing, OHD was loaded manually into two different compartments (8&#xa0;mg and 16&#xa0;mg). The tablets were characterized by their physicomechanical properties, dimensional fidelity, morphology, thermal and solid-state behavior (DSC, XRD), buoyancy, compartment integrity (dye test), and the in vitro drug release and release kinetics via mathematical models.</p> Result <p>All formulations exhibited acceptable hardness (4.0–6.4&#xa0;kg/cm²), friability (&lt; 1%) in the USP/IP range, immediate buoyancy (~ 3&#xa0;s), and prolonged floating (&gt; 20&#xa0;h). Microscopy revealed well-defined layered structures and hydrated PVA diffusion channels. Printing reduced polymer crystallinity without thermal degradation, as revealed via DSC and XRD. F3 achieved controlled biphasic release (~ 43.8%) and followed zero-order kinetics (R² = 0.9901) with non-Fickian transport.</p> Conclusion <p>FDM-based 3D printing provides precise architectural control over multicompartment tablets designing with customizable release behavior thereby representing a powerful platform for personalized and programmable oral drug delivery.</p> Summary <p>This work demonstrates how 3D printing can be used to redesign a conventional oral tablet into a programmable drug delivery system. A multicompartment gastroretentive floating tablet of OHD was produced using FDM, where tablet geometry was digitally controlled to regulate drug release. By varying wall thickness and orifice design, a biphasic release profile was successfully achieved, allowing an initial dose followed by sustained delivery. The printed tablets floated rapidly and remained buoyant for &gt; 20 h. Solid-state and thermal analyses confirmed that printing altered polymer crystallinity without degrading the drug, supporting the reliability of this manufacturing approach.</p> Word teaser <p>A 3D-printed multicompartment floating tablet was prepared to deliver OHD in a programmable biphasic manner, highlighting the potential of FDM printing for personalized gastroretentive therapy.</p>

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Design and Development of a 3D-Printed Multicompartment Gastroretentive Floating Tablet of Ondansetron Hydrochloride Dihydrate via Fused Deposition Modelling

  • 期刊论文

  • 发表日期：

    2026年3月24日

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  • Jyoti Kumari,
  • Krishna Kant Jangde,
  • Palanirajan Vijayaraj Kumar,
  • Sanjay Sharma,
  • Dinesh Kumar Mishra

摘要

Purpose

Personalized oral drug delivery requires an advanced manufacturing platform capable of programmable geometry and personalized release kinetics, especially for drugs that have an extended gastric retention period. This study developed and validated a multicompartment gastroretentive floating tablet of ondansetron hydrochloride dihydrate (OHD) using FDM 3D-printing and investigated whether geometrical modulation of compartment architecture could be exploited to achieve programmable biphasic drug release.

Methods

Polyvinyl alcohol (PVA) filament was chosen after screening of printability, mechanical strength, buoyancy, and release suitability. 3D-printed tablets (F1-F4) were designed via AutoCAD with varied wall-thicknesses and orifices structures and printed through optimized FDM parameters. During printing, OHD was loaded manually into two different compartments (8 mg and 16 mg). The tablets were characterized by their physicomechanical properties, dimensional fidelity, morphology, thermal and solid-state behavior (DSC, XRD), buoyancy, compartment integrity (dye test), and the in vitro drug release and release kinetics via mathematical models.

Result

All formulations exhibited acceptable hardness (4.0–6.4 kg/cm²), friability (< 1%) in the USP/IP range, immediate buoyancy (~ 3 s), and prolonged floating (> 20 h). Microscopy revealed well-defined layered structures and hydrated PVA diffusion channels. Printing reduced polymer crystallinity without thermal degradation, as revealed via DSC and XRD. F3 achieved controlled biphasic release (~ 43.8%) and followed zero-order kinetics (R² = 0.9901) with non-Fickian transport.

Conclusion

FDM-based 3D printing provides precise architectural control over multicompartment tablets designing with customizable release behavior thereby representing a powerful platform for personalized and programmable oral drug delivery.

Summary

This work demonstrates how 3D printing can be used to redesign a conventional oral tablet into a programmable drug delivery system. A multicompartment gastroretentive floating tablet of OHD was produced using FDM, where tablet geometry was digitally controlled to regulate drug release. By varying wall thickness and orifice design, a biphasic release profile was successfully achieved, allowing an initial dose followed by sustained delivery. The printed tablets floated rapidly and remained buoyant for > 20 h. Solid-state and thermal analyses confirmed that printing altered polymer crystallinity without degrading the drug, supporting the reliability of this manufacturing approach.

Word teaser

A 3D-printed multicompartment floating tablet was prepared to deliver OHD in a programmable biphasic manner, highlighting the potential of FDM printing for personalized gastroretentive therapy.