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 VOLUME Vol.05 Issue05 2025 

PAGE NO. 1-4 

 
 
 
 
 

Assessing the Usability of Reusable Cartridges in Semi-

Solid Extrusion 3D Printing for Pharmaceutical Drug 

Fabrication 
 

Dr. Mia Zhang 

Department of Biomedical Engineering, University of Queensland, Australia 

 

Dr. David Lee 

School of Pharmacy, University of Melbourne, Australia 

 

 

Received: 03 March 2025; Accepted: 02 April 2025; Published: 01 May 2025 

 

Abstract: Semi-solid extrusion (SSE) 3D printing is a promising technique for fabricating personalized medications. 
This study evaluates the usability of reusable cartridges in SSE 3D printing for drug fabrication. The research 
assesses the ease of use, cleaning efficiency, material compatibility, and print quality using reusable cartridges, 
comparing them to single-use counterparts. The findings highlight the potential of reusable cartridges to reduce 
waste and improve the sustainability of 3D-printed pharmaceuticals, while maintaining print quality and process 
efficiency. 

 

Keywords: Semi-Solid Extrusion (SSE), 3D Printing, Pharmaceutical Manufacturing, Drug Fabrication, Personalized 
Medicine, Reusable Cartridges, Additive Manufacturing, Printability, Formulation Stability, Material Compatibility. 

 

Introduction: Three-dimensional (3D) printing has 
emerged as a transformative technology in the 
pharmaceutical field, offering the potential for 
personalized drug delivery systems (Dumpa et al., 
2021; Tracy et al., 2023; Wang et al., 2023). Among the 
various 3D printing techniques, semi-solid extrusion 
(SSE) is particularly advantageous for drug fabrication 
due to its ability to process a wide range of materials, 
including viscous formulations and temperature-
sensitive drugs (Seoane-Viaño et al., 2021; Govender et 
al., 2021). SSE 3D printing involves extruding a semi-
solid material through a nozzle to create a 3D object, 
allowing for precise control over the shape, size, and 
internal structure of the final product (Mazarura et al., 
2022; Johannesson et al., 2021). 

A critical aspect of SSE 3D printing is the material 
delivery system, typically involving cartridges that hold 
the semi-solid formulation. Traditionally, single-use 
cartridges have been employed, raising concerns about 
increased plastic waste and environmental impact 
(Elliott et al., 2020; Cowan et al., 2021). In response to 

these concerns, reusable cartridges have been 
introduced as a more sustainable alternative. However, 
the usability of these reusable cartridges in the context 
of pharmaceutical applications, where stringent 
hygiene and quality control are paramount, requires 
thorough evaluation (Parhi, 2021). 

This study aims to evaluate the usability of reusable 
cartridges in SSE 3D printing for drug fabrication. It 
assesses the ease of use, cleaning efficiency, material 
compatibility, and print quality achievable with 
reusable cartridges, comparing them to single-use 
counterparts. The findings will provide valuable insights 
into the potential of reusable cartridges to enhance the 
sustainability of 3D-printed pharmaceuticals without 
compromising product quality or safety. 

METHODS 

The study involved a comparative evaluation of 
reusable and single-use cartridges in SSE 3D printing. 
The following methods were employed: 

1. Materials: A range of semi-solid formulations 

 



American Journal of Applied Science and Technology 2 https://theusajournals.com/index.php/ajast 

American Journal of Applied Science and Technology (ISSN: 2771-2745) 
 

 

with varying viscosities and compositions, 
representative of typical pharmaceutical materials, 

were used. 

 

Fig. Schematic presentation of the steps involved in the pressure-assisted microsyringe (PAM)-type 

extrusion-based 3D printing process. 

2. 3D Printing System: A commercially available 
SSE 3D printer was used, equipped with both reusable 
and single-use cartridge systems. 

3. Usability Assessment: 

o Ease of Use: The ease of filling, assembly, and 
disassembly of both cartridge types was evaluated 
through user trials with trained technicians. 

o Cleaning Efficiency: A standardized cleaning 
protocol was developed, and the effectiveness of 
cleaning procedures for reusable cartridges was 

assessed using visual inspection and residual material 
analysis. 

o Material Compatibility: The chemical 
compatibility of cartridge materials with the selected 
formulations was assessed to ensure no degradation or 
leaching occurred. 

o Print Quality: The dimensional accuracy, 
uniformity, and structural integrity of printed objects 
were evaluated using techniques such as microscopy 
and texture analysis. 

  

 

Fig. Lessons to learn for 3D printing of drug products by semisolid extrusion (SSE) 



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American Journal of Applied Science and Technology (ISSN: 2771-2745) 
 

 

4. Regulatory Considerations: The study 
considered the regulatory perspectives on 3D printing 
in pharmaceuticals, particularly regarding the use of 
reusable components and potential cross-
contamination risks (Khairuzzaman, 2018). 

RESULTS 

The results of the study indicate the following: 

• Ease of Use: Reusable cartridges were found to 
be slightly more complex to assemble and disassemble 
compared to single-use cartridges. However, with 
proper training, the process was manageable. 

• Cleaning Efficiency: The established cleaning 
protocol effectively removed residual material from 
the reusable cartridges, with no significant carryover 
observed. 

• Material Compatibility: The cartridge materials 
exhibited good compatibility with the tested 
formulations, showing no signs of degradation or 
leaching. 

• Print Quality: The print quality achieved with 
reusable cartridges was comparable to that of single-
use cartridges, with no significant differences in 
dimensional accuracy, uniformity, or structural 
integrity. 

DISCUSSION 

The findings suggest that reusable cartridges offer a 
viable alternative to single-use cartridges in SSE 3D 
printing for drug fabrication. While there may be a 
slight increase in complexity regarding assembly and 
disassembly, the cleaning protocols can be effective in 
preventing cross-contamination. 

The adoption of reusable cartridges can significantly 
reduce plastic waste, aligning with the growing 
emphasis on sustainability in pharmaceutical 
manufacturing (Kasznik & Łapniewska, 2023). The 
economic benefits of reduced material consumption 
and waste disposal costs further support their 
implementation. 

It is crucial to adhere to stringent cleaning and 
sterilization procedures to mitigate the risk of cross-
contamination, especially when processing different 
drug formulations. Further research is needed to 
optimize cartridge design and cleaning protocols, and 
to address long-term durability and performance. 

CONCLUSION 

Reusable cartridges present a promising approach to 
enhance the sustainability of SSE 3D printing for drug 
fabrication. With proper handling and cleaning 
procedures, they can effectively replace single-use 
cartridges without compromising print quality or 
safety. The adoption of this technology can contribute 

to a more environmentally friendly and economically 
viable approach to personalized medicine. 

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