Harnessing handheld inkjet printing technology for rapid and decentralised fabrication of drug-loaded hydroxypropyl cellulose buccal films

• Handheld inkjet printer allows precise dosing of nicotine on HPC/Eudragit NE 30 d films. • Nicotine dose can be flexibly chosen by tuning area and layers of pharma-ink printed. • The film withstands 3 printed layers of nicotine ink with minimal structural changes. • Although nicotine migrates in the film, the release is rapid and facilitates buccal permeation. • Handheld printing of pharma-inks on sustainable films is a green approach for local production of personalized medicines. Inkjet printing is emerging as a valuable tool for personalised medicine, offering precision and flexibility in pharmaceutical development. Efforts have been made to modify commercial desktop printers; however, the growing interest in decentralized and on-demand pharmaceutical production highlights the need for more compact, energy-efficient alternatives that enhance versatility and seamless integration across diverse environments. This study presents for the first time, a handheld inkjet printer for the portable production of personalised medications in decentralised settings using hydroxypropyl cellulose (HPC) films as the printing substrate. The compact design of handheld printers ensures ease of use, space efficiency, and reduced energy consumption, making them ideal for patient-centric applications. As a proof of concept, the Selpic S1+ handheld inkjet printer was used to create buccal films with flexible nicotine doses tailored for nicotine replacement therapy. By modifying the printed area and number of pharma-ink (drug-loaded pharmaceutical ink) layers, precise nicotine dosages were achieved. The films exhibited controlled drug release, strong mucoadhesive properties, and adequate mechanical properties for buccal application. Studies on swelling behaviour, mucoadhesion, and surface morphology validated the film structural integrity and functionality. Ex vivo permeation studies using porcine buccal mucosa demonstrated high nicotine permeability. Additionally, pharma-ink printing was successfully applied to other biological macromolecules substrates (starch and cellulose), underscoring the versatility of handheld devices in creating diverse patterns across different surfaces. This research highlights the potential of handheld inkjet printing on eco-friendly films for decentralised, rapid and affordable treatment customisation with improved therapeutic outcomes and patient adherence.