Multi-Material 3D Printing and Computational Design in Pharmaceutical Tablet Manufacturing

Multi-material 3D printing has revolutionized pharmaceutical tablet manufacturing by enabling unprecedented control over the spatial arrangement of active pharmaceutical ingredients (APIs) and excipients. This systematic review analyzes the significant advances in computational methods and 3D printing technologies for pharmaceutical applications from 2005 to 2024. The review explores the integration of artificial intelligence and evolutionary algorithms in solving complex inverse problems of tablet design, where computational methods achieve better accuracy in predicting drug release profiles. Recent developments in material science, including novel thermoresponsive polymers and stimuli-responsive materials, have enhanced manufacturing capabilities while maintaining drug stability. Clinical trials and real-world implementations demonstrate improvements in therapeutic outcomes, with personalized 3D printed medications showing enhanced treatment efficacy and better safety profiles compared to conventional formulations. The review also addresses critical challenges in regulatory compliance, quality control, and scale-up processes, providing a framework for future developments in personalized medicine manufacturing. This work synthesizes current knowledge and identifies emerging trends, offering insights into the future direction of pharmaceutical 3D printing technology and its implications for personalized medicine.