Beyond the Hype: The potential and challenges of semi-solid extrusion 3D Printing in pharmaceutical applications through the lens of Portuguese 3D experts

In recent years, the technological landscape has experienced a notable surge in the exploration of 3D Printing technologies (3DPT), particularly as an additive manufacturing method. Among the various 3DPT available, semi-solid extrusion 3DP (SSE-3DP) has emerged as a prominent solution for pharmaceutical applications, owing to its versatility and adaptability for customization. Nevertheless, achieving further technological advancement is hindered by a myriad of challenges related to materials, process, and quality control. Therefore, this research aimed to explore, uncover, and critically discuss both the potential and the challenges of SSE-3DP, by capturing the insights, vision, and perspectives of Portuguese 3DP experts, through a focus group analysis. The focus group discussions revealed an initial sense of positivity, fascination, and novelty regarding the technology, later evolving into mixed emotions of doubt and aspiration, effectively highlighting both the challenges and opportunities that lie ahead for the advancement of SSE-3DP. Moreover, the analysis yielded a total of 148 sub-codes, related to materials, process, printers' specifications, quality control testing, needs and lack of knowledge, solutions, business applications and personalization strategies. Notably, 3DP experts underscored the necessity for investment in multi-materials research, printer functionalities, process optimization through automation and artificial intelligence (AI) or advanced dynamic tools, and quality control using standard guidelines or machine learning models. Overall, this article provides a foundational framework for future research, addressing the gaps, needs, and solutions highlighted by 3DP experts.