Development and evaluation of a 3D/FDM-printed chewable 6-mercaptopurine tablet for dose individualization in pediatric acute lymphoblastic leukemi
“Pharmaceutical 3D printing, Pediatric chewable tablet, 6-mercaptopurine, Dose personalization, Acute lymphoblastic leucemia.
“Acute lymphoblastic leukemia is the most prevalent malignant disease in childhood, and its maintenance therapy relies on long-term oral administration of drugs such as 6-mercaptopurine (6MP). However, the commercially available dosage form presents significant limitations for pediatric use, including poor palatability, limited dose flexibility, and difficulties in tablet splitting, which may negatively impact treatment adherence and therapeutic safety. Within this context, this dissertation aimed to develop a pediatric chewable tablet containing 6-MP produced by fused deposition modeling (FDM) 3D printing, targeting a safe, effective, and patient-tailored pharmaceutical dosage form. The methodological approach included a rational excipient screening based on Hansen solubility parameters, followed by physicochemical compatibility studies using differential scanning calorimetry and thermogravimetric analysis, as well as rheological evaluation of the filaments to ensure printability. The printed tablets were characterized in terms of weight and content uniformity, porosity, optical microscopy of filaments and tablets, mechanical properties related to chewability, dissolution, disintegration, and drug content by HPLC, in addition to the investigation of in situ nanoparticle formation during dissolution. The results demonstrated good compatibility between 6MP and all selected excipients, absence of thermal degradation at extrusion and printing temperatures, and suitable rheological behavior of the filaments, ensuring reproducible manufacturing. The tablets exhibited a homogeneous structure with a well-distributed porous network, chewability appropriate for pediatric patients, compliant drug content and uniformity, and dissolution and disintegration profiles comparable to the commercial 6-MP tablet. Moreover, evidence of in situ nanoparticle formation during dissolution was observed, suggesting a potential biopharmaceutical advantage. Overall, the developed 3D-printed chewable tablet demonstrated safety and performance equivalent to the marketed product, while offering additional benefits related to dose personalization and patient acceptability, highlighting its strong potential for future clinical application in pediatric leukemia therapy.”