3D-Printed Pharmaceutical Packaging Molds for Precise Dose Customization
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Solution Overview
Problem
Existing 3D printing technologies are limited in producing pharmaceutical objects like tablets, granules, and capsules, leading to waste, high costs, and inability to produce non-porous forms, and are not suitable for individual user customization.
Innovation Solution
A 3D printing system with a movable print head, cartridges for various substances, and a mechanical system allowing for precise layering and shaping of pharmaceutical objects, including tablets, granules, and capsules, using a variety of active and excipient substances, with features like temperature control and cleaning units.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a moving belt method is used to apply powdered mixture and spray binding fluid, then porous tablets can be produced, but feedstock waste increases and manufacturing versatility is limited
Solution Approach 1:
The system divides the printing process into discrete layer deposition steps using a print head that applies material layer by layer, rather than continuously applying powder and binding fluid. This segmentation allows precise control over material usage and eliminates waste from unutilized feedstock.
Solution Approach 2:
The invention changes the fundamental parameter of material application from continuous spray/deposition to discrete layer placement. By controlling the print head to deposit specific amounts of material layer by layer, the system achieves both porous tablet production and minimal waste.
2Productivity
If continuous layer application is used to produce porous tablets, then tablet formation is achieved, but manufacturing versatility is reduced to only porous tablets
Solution Approach 1:
The print head system is designed to be universal, capable of producing different pharmaceutical forms (porous tablets, compact tablets, granules, capsules) by adjusting deposition parameters and material properties. This multi-functionality eliminates the need for separate manufacturing lines for different product types.
3Adaptability or versatility
If traditional pharmaceutical production methods are used, then various pharmaceutical forms can be produced, but production costs and labor costs are high
Solution Approach 1:
The system merges multiple manufacturing functions into a single 3D printing platform. The print head can produce different pharmaceutical forms by programming changes, eliminating the need for separate production lines and reducing overall manufacturing complexity and cost.
Solution Approach 2:
The system enables self-service customization where the print head can be programmed to produce specific pharmaceutical forms according to individual prescriptions or requirements, reducing the need for expensive specialized equipment and labor in traditional pharmaceutical manufacturing.
4Quantity of substance
If bulk pharmaceutical production is used, then large quantities can be produced, but storage costs and waste from unused medications increase
Solution Approach 1:
The print head system enables local quality customization by producing small batches or individual doses with precise control over material composition and form. This eliminates the need for bulk storage and reduces waste from unused medications, while still allowing production of required quantities on demand.
Data Source
AI summary
Method for 3D printing, comprising the following steps: providing a packaging (2′) having at least one recess (3′) for receiving a product (1′), wherein the shape of the recess (3′) corresponds at least in part to the shape of the product (1′) and wherein the recess (3′) forms a protuberance at the other side of the packaging (2′); providing a 3D printer with a print base (5′) having at least one recess (6′) for receiving the protuberance formed by the recess (3′) of the packaging (2′); inserting the packaging (2′) in the print base (5′) such that the protuberance formed by the recess (3′) of the packaging (2′) is received by the recess (6′) of the print base (5′); filling a print head (7′) of the 3D printer with at least one material for printing the product (1′); 3D printing the product (1′) inside the recess (3′) of the packaging (2′), wherein the part of the recess (3′) corresponding to the shape of the product (1′) serves as the mold and print support, resp., for those layers of the product (1′) which are 3D printed first. The method is performed with a system for 3D printing, comprising a packaging (2′) having at least one recess (3′) for receiving a product (1′), wherein the shape of the recess (3′) corresponds at least in part to the shape of the product (1′) and wherein the recess (3′) forms a protuberance at the other side of the packaging (2′); and a 3D printer with a print head (7′) and a print base (5′); characterized in that the print base (5′) has at least one recess (6′) for receiving the protuberance formed by the recess (3′) of the packaging (2′) to support the packaging (2′) with the recess (3′) such that the product (1′) can be 3D printed inside the recess (3′) of the packaging (2′), wherein the part of the recess (3′) corresponding to the shape of the product (1′) serves as the mold and print support, resp., for those layers of the product (1′) which are 3D printed first.