Evaluating Sustainable Material Choices for 3D-Printed Pharmaceuticals in the UK Manufacturing Sector: A Comprehensive Review

Abstract

The emergence of three-dimensional (3D) printing has transformed pharmaceutical development by enabling personalised, flexible, and digitally controlled manufacturing workflows. As the United Kingdom advances toward greener production models and precision medicine, material selection for pharmaceutical fused deposition modelling (FDM) has become a critical determinant of both product performance and environmental sustainability. This review examines the sustainability, functional suitability, and regulatory implications of three key filament classes polylactic acid (PLA), polyvinyl alcohol (PVA), and cellulose-based materials within the context of UK pharmaceutical manufacturing. Drawing on scientific evidence and qualitative insights from industry practitioners and academic researchers, the review evaluates each material’s printability, biocompatibility, environmental impact, drug-polymer compatibility, and operational feasibility. PLA and cellulose-based filaments offer favourable biodegradable and renewable profiles, whereas PVA remains the most pharmaceutically versatile but presents environmental burdens. The analysis highlights the need for life-cycle assessment frameworks, material innovation, and regulatory alignment to support sustainable 3D-printed medicines. Recommendations are provided to guide UK manufacturers, policymakers, and pharmaceutical scientists toward responsible material choices that balance performance, safety, and environmental stewardship.