Extrusion and 3D printing of novel lipid-polymer blends for oral drug applications

Lipids are interesting biological materials that can offer a number of pharmaceutical benefits when used as carriers for drug delivery. However, 3D printing of lipids alone by fused deposition processing techniques is very difficult as they have very poor mechanical properties that cause their filaments to fail when they are loaded into a fused deposition 3D printer. If this problem could be overcome, then lipids could be 3D printed into bespoke tablets and assist progress towards such personalised medicines. This work aims to improve the mechanical properties of lipid filaments by developing novel lipid-EVA (ethylene vinyl acetate) blends suitable for 3D printing. Different types of lipids in varying proportions were melt blended with EVA and extruded using a micro compounder. The ultimate printability of the materials was tested by feeding the filaments into a material extrusion 3D printer. Flexural testing of the extruded blends demonstrates that a good balance between the strength and flexibility is required for a material to be printable and it was found that a filament has to have a modulus/strength ratio between 8 and 25 in order to be printable. SEM analysis of the fracture surface shows a network structure within the lipid matrix that could be playing a role in the improved properties of the best performing blends. DSC thermograms show a shift in thermal transitions, suggesting some level of miscibility of the components that could have contributed to a more robust structure. The TGA results show an onset of degradation of the blends greater than 200 °C, indicating that the materials can readily withstand the extrusion and printing temperatures. This study demonstrates the successful extrusion and 3D printing of novel EVA-lipid blends with lipid contents of up to 90%.