This study investigates the applicability and advantages of using additive manufacturing to moderate heat generation in dry milling. Grinding medium balls of different sizes were designed and fabricated using computer-aided design (CAD) and a stereolithographic 3D printer. Milling processes with particle size distribution and warmup measurements were employed with the printed medium balls. The results were compared with the measurements executed with conventional stainless-steel balls. Differential scanning calorimetry (DSC) was employed to evaluate the effect of the warmup of the system during the milling process. A two-variable, three-level experimental design was used for the measurements. We selected two grinding parameters considered critical: speed and time. The effect of these two independent variables on heating was examined. The results show that if printed balls are applied with the same total mass as that of metal balls, the particle size reduction is increased. The greater the number of balls used, the greater the particle size reduction. In this process, where additively manufactured milling bodies were used, the temperature of the system increased by less than when stainless-steel balls were used. The use of 3D-printed medium balls demonstrated beneficial warmup behavior.

Background/Objectives: The growing demand for personalised, patient-centric drug delivery systems has driven innovation in pharmaceutical manufacturing, particularly in multi-unit particulate systems (MUPS). Methods: In this study, inert cores with tailor-made geometry for multi-particulate formulations were fabricated with high-resolution stereolithography (SLA) 3D printing. By a printable photopolymer resin, dimensionally accurate and mechanically robust starter cores were produced. The additively manufactured inert subunits were drug-layered with ibuprofen sodium using a fluidised bed process. Then, a controlled-release film coating of Eudragit RS 30D was applied with varying coating thicknesses. The initial 3D-printed subunits, together with the drug-layered and finally film-coated microparticles, were characterised by image analysis, Raman microspectroscopic measurements, and official methods of the European Pharmacopoeia. Results: The combined approach of 3D printing and traditional pharmaceutical processing proved highly effective. The 3D-printed cores demonstrated both flexibility in design and consistency in performance. Conclusions: These findings highlight the feasibility of using 3D printing to produce patient-specific, functional cores in multi-particulate systems that can be easily modified according to the patient’s needs. The fabricated minitablets can be used as alternatives to widely used inert cores. Integrating additive manufacturing with conventional coating techniques offers promising new avenues for developing next-generation, personalised drug delivery solutions.