Background: Pharmaceutical compounding remains a predominantly manual process with limited innovation, particularly in non-sterile applications. This study explores the implementation of an automated compounding platform based on 3D printing to enhance precision, efficiency, and adaptability in pediatric corticosteroid formulations. Methods: Personalized hydrocortisone dosage forms were prepared in a hospital pharmacy setting using a proprietary excipient base and standardized procedures, including automated dosing and syringe heating when required. Three dosage forms—3.2 mg gel tablets, 2.8 mg water-free troches, and 1.2 mg orodispersible films (ODFs)—were selected to demonstrate the platform’s versatility and to address pediatric needs for varying strengths and dosage types. All products were prepared using a reproducible semi-solid extrusion (SSE)-based workflow with the consistent API-excipient blending and automated deposition. Results: Analytical testing confirmed that all formulations met pharmacopeial criteria for mass and content uniformity. The ODF and troche forms achieved rapid drug release, exceeding 75% within 5 min, while the gel tablet showed a slower release profile, reaching 86% by 60 min. Additionally, in-process homogeneity testing across syringe printing cycles confirmed the consistent API distribution. Conclusions: The results support the feasibility of integrating automated compounding technologies into pharmacy workflows. Such systems can improve accuracy, minimize variability, and streamline the production of customized pediatric medications, particularly for drugs with poor palatability or narrow therapeutic windows. Overall, this study highlights the potential of automation to modernize non-sterile compounding, and to better support individualized therapy.

Background: Tablet splitting is widely used to individualize dosing of metoprolol tartrate when low-dose formulations are unavailable. However, splitting may lead to variability in dose accuracy, which can be clinically relevant at low dose strengths. This study compared the accuracy and precision of manual tablet splitting versus automated 3D printing for producing low-dose metoprolol tartrate tablets in a hospital setting. Methods: Commercial 25 mg metoprolol tartrate tablets from two manufacturers were manually split at Mayo Clinic into 12.5 mg halves and 6.25 mg quarters following established procedures. CurifyLabs’ Compounding System, including the Pharma Printer and CuraBlend^®-based formulations, was used at two hospital pharmacy sites and a compounding pharmacy to produce 6.25 mg and 12.5 mg tablets via 3D printing. Mass variation and content uniformity were evaluated using USP criteria and validated HPLC methods. Results: Manually split tablets showed high variability, with 6.25 mg quarters ranging from 24.9% to 142.8% API content and 12.5 mg halves from one manufacturer averaging only 66.6%, indicating frequent underdosing. In contrast, 3D-printed tablets achieved mean API contents within 90–103%, standard deviations below 5%, and acceptance values under 15 across all sites and formulations. Conclusion: Manual tablet splitting may not reliably meet pharmacopeial expectations for dose accuracy and content uniformity at lower dose strengths. Automated 3D printing produced consistent low-dose tablets and may offer a validated alternative where available.