Smart Pills, Smarter Printing: AI In 3D Printing Of Oral Dosage Forms

Abstract

The convergence of Artificial Intelligence (AI) and pharmaceutical three-dimensional (3D) printing is proving to be a promising strategy for creating more precise and adaptable oral drug delivery systems. The review investigates the potential of AI-driven 3D printing to address some of the drawbacks of traditional manufacturing, by offering enhanced control over formulation composition, dosage, product geometry and drug release behaviour. The various 3D printing technologies used for oral dosage forms, for example, fused deposition modelling, semi-solid extrusion, binder jetting, inkjet printing, stereolithography and selective laser sintering, are explained and discussed with respect to their pharmaceutical application. Special attention is paid to the application of machine learning and computational modeling in formulation optimization, predictability of printability, process parameter selection, drug release prediction and monitoring of quality. The review also highlights the potential of these technologies for patient-specific dosage forms, including customized tablets, oral films, chewable formulations and polypills. Recent developments indicate a growing transition of 3D printing systems from research towards practical applications as the systems become more viable and patient oriented. But issues concerning printable pharmaceutical materials, equipment expense, data quality, model validation, regulatory requirements, cybersecurity, and industrial scalability continue to be significant hurdles for broader implementation. Future innovations like digital twins, autonomous AI-driven printing, Internet of Things (IoT) and Explainable AI (XAI) can still redefine pharmaceutical production, offering the potential for more intelligent production and real-time process control. Overall, AI-integrated 3D printing represents a significant step towards flexible, data-driven and personalized manufacturing of oral dosage forms.