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Porous pills were predicted in 2015 to become the largest-volume mass-manufactured product made with 3D printing. That was a forecast, not a confirmed current ranking. The example behind it was Spritam, Aprecia’s 3D-printed levetiracetam tablet: its porous structure lets liquid penetrate quickly, helping the tablet disintegrate for patients who have difficulty swallowing.
What the “largest industrial use” claim meant
The phrase came from a forecast attributed to MIT researcher Michael Cima in a Chemistry World report published on 20 August 2015. Discussing Aprecia’s Spritam, Cima said the dosage forms could soon become the largest-volume mass-manufactured objects made using these techniques. The available reporting does not establish that this prediction came true, and it does not provide a current market-size comparison across industrial 3D-printing applications.
The timing matters: the article appeared as Spritam received FDA approval. The prediction concerned the potential manufacturing volume of this product category, not proof that porous pills already dominated industrial 3D printing.
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Aprecia’s ZipDose process
Aprecia made Spritam, a reformulation of the anti-seizure medicine levetiracetam, using its ZipDose process. In the 2015 report, Aprecia intellectual-property manager Thomas West described spreading thin layers of powder and selectively depositing liquid droplets to bind the powder layer by layer into a three-dimensional form. This is binder jetting: liquid binder is applied selectively to powder rather than shaping the whole tablet from a conventional solid mass.
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Why porosity affects the dose
The resulting tablet has a highly porous structure. Water can move into it and help it break apart rapidly. Chemistry World reported that Spritam dispersed in water after four seconds; that is a figure reported for this particular formulation and process, not a general disintegration time for porous pills.
The structure also offered a way to incorporate a high dose in one tablet. A Nature Biotechnology report published on 8 October 2015 said the technology could produce individual pills containing up to one gram of drug. That is a historical report about the technology’s capability, not a specification for every Spritam tablet or every 3D-printed medicine.
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What benefit the design is intended to provide
A rapidly disintegrating tablet can be easier to administer to someone who struggles to swallow a large pill. The 2015 Chemistry World article placed this in the context of children with epilepsy and reported that around a sixth of nearly three million people with epilepsy in the United States were children. Those are dated figures from that report, not a current prevalence estimate.
Rapid disintegration is a delivery and administration feature. It does not, by itself, show that the medicine works better clinically than another formulation containing the same active ingredient. Nor should a result reported for Spritam be generalized to all porous tablets: performance depends on the formulation, materials, printing parameters and intended release profile.
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How pharmaceutical 3D-printing methods differ
Porous fast-disintegrating tablets are one use of pharmaceutical 3D printing, not the only one. A 2025 review of 3D printing in oral drug delivery describes research into customized doses, layered or combined medicines, and designs intended to control drug release. These are areas of development; their discussion does not mean all such products are routine commercial medicines.
| Method | Potential strengths described in the 2025 review | Important tradeoffs |
|---|---|---|
| Binder jetting | Can produce highly porous tablets and avoids heat during printing. | Lower mechanical strength can be a concern, and the method has limitations for extended-release forms. |
| Selective laser sintering | Can create porous structures and customized release designs. | Heat can constrain use with sensitive ingredients; pharmaceutical-material compatibility is also a challenge. |
| Fused deposition modeling | Accessible and potentially cost-effective. | Active ingredients may be exposed to heat, and suitable materials are required. |
No method is automatically best for every drug. A development team has to match the printing method to the active ingredient and excipients, desired release profile, tablet geometry and strength, production throughput, reproducibility, and regulatory requirements.
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Why a promising formulation is not automatically an industrial-scale success
Manufacturing a medicine reliably at scale involves more than printing a workable tablet once. The 2025 review identifies several barriers to broader pharmaceutical use:
- Finding pharmaceutical-grade materials that are compatible with the drug and remain stable.
- Getting repeatable results as printing parameters or production conditions change.
- Meeting regulatory expectations, particularly for small-batch or decentralized production.
- Managing equipment and material costs, production speed, and the need for specialized expertise.
These constraints help explain why a notable approved product is not enough to verify a broad industrial ranking. The cited sources describe a specific product and the promise and challenges of pharmaceutical printing; they do not establish the current volume of printed pills relative to other 3D-printed goods.
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Other printed-tablet designs are not the same as Spritam
Pharmaceutical printing can pursue goals opposite to fast disintegration. In a 2025 MIT News report, Enzian Pharmaceutics was developing an investigational fibrous tablet designed to expand and release medicine over time. The company reported animal-study retention of 12 to 24 hours and validation in a small number of healthy volunteers at the time of the report. Those results concern a different design and stage of development; they should not be confused with Spritam’s rapid-dispersing porous tablet. The article also attributed to Enzian co-founder Aron Blaesi a statement that peak-to-trough blood concentrations can differ by up to 50 times for some oral cancer drugs. That is interview context about some medicines, not a general statistic for cancer treatments.
Did porous pills become the largest industrial use?
The cited sources do not answer that question. The “largest” wording was a 2015 prediction, and neither the later pharmaceutical review nor the 2025 MIT News article establishes a current ranking or market share for porous pills across industrial 3D printing. What the reporting does support is narrower: Aprecia’s Spritam was reported as the first FDA-approved 3D-printed prescription medicine, and its binder-jetted porosity served a practical formulation purpose. Whether that category became the largest industrial application remains unverified by these sources.
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