FORMULATION STRATEGIES FOR SELECTIVE LASER SINTERING IN PHARMACEUTICAL 3D PRINTING

Abstract

Selective Laser Sintering (SLS) is an advanced powder-based 3D printing technology that has gained significant attention in pharmaceutical formulation development. In SLS, a high-energy laser selectively sinters powdered materials layer by layer to form solid dosage forms without the need for solvents or binders. The formulation used in SLS printing plays a crucial role in determining the quality, mechanical strength, drug release behavior, and stability of the final product. Typically, SLS formulations consist of a drug, polymeric carriers such as polyvinyl alcohol (PVA), polyethylene glycol (PEG), or polycaprolactone (PCL), and suitable additives like fillers or absorbers to enhance laser energy absorption. The particle size, flow properties, and thermal characteristics of the powder blend are critical parameters affecting printability and sintering efficiency. SLS enables the production of personalized dosage forms with complex geometries, controlled porosity, and modified drug release profiles. Additionally, it allows the fabrication of immediate-release, sustained-release, and multi-drug dosage forms. Despite its advantages, challenges such as thermal degradation of drugs and limited availability of pharmaceutical-grade polymers remain. Overall, SLS 3D printing formulation represents a promising approach for personalized medicine and innovative drug delivery systems.