Fabrication and biocompatibility evaluation of 3D printed tablets using Digital Light Processing (DLP) printing for the controlled release of ketoprofen.

Digital Light Processing (DLP) is a widely utilized additive manufacturing (AM) technique in pharmaceutical research that operates via photopolymerization. This technology enables the fabrication of advanced drug delivery systems through the use of novel polymeric materials that can be precisely tailored to meet the requirements of specific dosage forms. In the present study, three-dimensional (3D) printed tablets were developed to achieve controlled release of the non-steroidal anti-inflammatory drug ketoprofen (Keto). Comprehensive physicochemical characterization, including thermal analysis, Fourier Transform Infrared (FTIR) spectroscopy, and Nuclear Magnetic Resonance (NMR) spectroscopy, confirmed the successful incorporation of the active pharmaceutical ingredient (API) within the polymer matrix and demonstrated its chemical stability following the photopolymerization process. In vitro drug release studies revealed controlled release profiles of Keto from the printed formulations, with the overall extent of drug release remaining limited to less than 20% after 24 h, highlighting the important aspect the important role of the starting materials (polymers) that requires further optimization. Morphological evaluation using optical microscopy and scanning electron microscopy (SEM) demonstrated uniform tablet geometry and smooth surface characteristics. Biocompatibility studies conducted using Caco-2 cells indicated that the formulations were non-toxic and suitable for oral administration. Furthermore, confocal laser scanning microscopy (CLSM) analysis showed preserved cellular morphology and membrane integrity after exposure to the formulations. These findings underscore the potential of photopolymerization-based 3D printing technologies as a versatile and effective platform for the fabrication of biocompatible solid drug delivery systems with customizable drug release behavior.