3D printed mucoadhesive films: Individualized drug dosing for localized drug delivery

Mucoadhesive films enable non-invasive and localized drug delivery. Among various manufacturing methods, this study focuses on fused deposition modeling (FDM) using an advanced two-nozzle 3D printing system. This technique allows the fabrication of two-part films containing spatially separated verum (drug) and placebo segments, enabling flexible and individualized drug dosing within a single dosage form. Caffeine was used as a model drug to produce and compare 3D printed films with those made by solvent casting (SC). Mechanical, optical, and dissolution properties were assessed. While SC films showed higher extensibility and lower tensile strength, 3D printed films—especially the two-part designs—exhibited greater tensile strength but reduced flexibility. Both SC and 3D printed films showed similar mucoadhesive properties, indicating that the manufacturing method does not significantly influence adhesion to mucosal surfaces. Two-nozzle printing approach proved effective in precisely combining verum and placebo regions, offering potential for site-specific drug delivery, such as treatments targeting the esophagus. Additionally, drug loading can be adjusted by varying the ratio between placebo and verum filaments. This work highlights the versatility of multi-material 3D printing for producing mucoadhesive films and paves the way for personalized therapies across different indications.