3D printing of pediatric drug delivery systems: advances in personalized formulations and translational applications

Pediatric pharmacotherapy faces challenges due to developmental variability, lack of age-appropriate formulations, individualized dosing requirements, and adherence issues. Conventional dosage forms often fail to provide flexibility needed for pediatric use. Three-dimensional printing offers a versatile platform for producing personalized drug products with precise control over dose, geometry, and palatability. This review outlines key 3D printing technologies, including fused deposition modeling, semisolid extrusion, inkjet printing, and stereolithography, and their applications in pediatric drug delivery. Innovations such as orodispersible films, chewable formulations, micro-dosing systems, and polypills demonstrate improved dosing accuracy, taste masking, and polypharmacy management. This review also discusses material considerations, including the pediatric suitability, safety, and stability of excipients such as polyvinyl alcohol, polylactic acid, and hydroxyl-propyl methylcellulose. Clinical examples highlight translational progress in this field. Additionally, sensory design factors, including shape, color, and flavor, are emphasized for enhancing acceptability. Contrary to other studies that have mainly concentrated on technicalities of 3D printing technology or have been concerned with drug delivery methods in general, this study presents a translational approach toward 3D printing in pediatrics by considering formulation science, sensory considerations, regulation, and clinical relevance. This study is unique because it highlights the importance of matching technology, formulation, and patients.