3D-Printed Shellac-Based Delivery Systems: A Biopolymer Platform for Intestinal Targeting of Biologically Active Compounds

This study presents the development of 3D-printed shellac-based devices designed for site-specific intestinal delivery of bioactive compounds. The devices were fabricated using fused deposition modeling (FDM) 3D printing technology, employing a shellac filament plasticized with 20% w/w poly-(ethylene glycol) 10000 (PEG 10000). The influence of structural parametersspecifically base thickness (0.5-2 mm) and lateral wall thickness (1-2 mm)on mechanical performance, disintegration behavior, and release kinetics was systematically evaluated using propranolol hydrochloride as a model bioactive compound. Characterization via scanning electron microscopy (SEM), mechanical testing, and thermal analysis confirmed the successful fabrication of devices with a consistent morphology and robust mechanical properties. Increased thickness notably enhanced the mechanical strength and modulated the release profiles. Disintegration and dissolution testing demonstrated that thicker devices resisted acidic degradation while enabling timely release under simulated intestinal conditions. These results underscore the versatility of shellac-based 3D-printed platforms for precise, delayed, and site-specific intestinal releasenot only for pharmaceutical agents but also for sensitive macromolecules, probiotics, enzymes, and nutraceuticals requiring protection from gastric degradation.