Influence of Infill Pattern on Ketoprofen Release Rate from 3D Printed Buccal FilmsInfluence of Infill Pattern on Ketoprofen Release Rate from 3D Printed Buccal Films.

OBJECTIVE: To evaluate whether fused deposition modeling (FDM) 3D printing, combined with a simple filament soaking technique and modifications of infill pattern geometry, can modulate the release rate of ketoprofen from buccal films.Significance: This proof-of-concept approach explores a low-complexity strategy for producing personalized buccal dosage forms with adjustable drug release using commercially available materials and minimal processing steps. METHODS: Polyvinyl alcohol (PVA) filaments were loaded with ketoprofen by soaking in a saturated ketoprofen solution in absolute ethanol. Buccal films were 3D-printed using two infill patterns (lines and triangle). Drug content was quantified by UV/Vis spectrophotometry. Solid-state characterization was performed using DSC and FTIR. Dissolution testing was conducted for 120 min in 200 mL phosphate buffer (pH 6.8). RESULTS: Ketoprofen-loaded films were successfully printed from soaked commercial PVA filaments. DSC and FTIR indicated conversion of ketoprofen to an amorphous form and possible solid dispersion formation within the polymer matrix. Infill geometry influenced drug release: triangle-pattern films showed slower release (79 ± 2% at 120 min) compared with line-pattern films (96 ± 5% at 120 min). CONCLUSIONS: Combining filament soaking with FDM 3D printing enables fabrication of ketoprofen buccal films with sustained release. Simple infill pattern modifications effectively modulate release profiles, highlighting the potential of this accessible approach for personalized buccal drug delivery.