Fabrication of Montelukast sodium loaded filaments and 3D printing transdermal patches onto packaging material.

The main objectives of this work were to develop and characterize new 3D printing filaments and print them directly onto a packaging material. Different blends of polymers were tested to achieve low-temperature printing filaments, which are flexible and durable to be wound onto spools. The mechanical properties of filaments were compared with commercial filaments and evaluated by bending tests. Kollidon 12PF, PEG 4000, and PEO 900k blends resulted in promising filaments that could be extruded at 70 °C and had flexibility similar to commercial PLA filaments. Montelukast sodium (MS), which undergoes hepatic first-pass metabolism, was compounded into polymer blends, and drug-loaded filaments were extruded. All filaments were tested with a 3D printing pen prior to using with the 3D printer for transdermal patches. MS loaded filaments and patches showed similar flexibility with placebo. In vitro drug release studies showed 52% of MS was released in 24 h. Printing on disposable packaging material is presented for the first time with this study. Build plate adhesion and cohesion of 3D printed layers were successfully achieved. This new technique could prevent cross-contamination, save time, and provide ease of use, which can take us one step closer to the production of personalized drugs in pharmacies.