Integrated formulation–process strategies for optimised extrusion and printability outcomes in additive manufacture of oral solid dosage forms

About the Project

Details of the Project

Extrusion-based three-dimensional (3D) printing has emerged as a promising platform for delivering personalised solid oral dosage forms however, its broader adoption remains constrained by limited throughput, variable dose uniformity, and inconsistent print reliability. This project seeks to optimise extrusion performance through coordinated advances in feedstock formulation and extrusion control. By integrating materials science, pharmaceutical engineering, and process analytics, the study aims to define robust, scalable strategies that enhance extrudability while meeting stringent quality requirements.

The first objective is to engineer hot-melt extrusion (HME) filaments and semi-solid extrusion (SSE) pastes with rheological properties tailored for continuous, stable deposition. Formulation work will focus on polymer-based systems, active pharmaceutical ingredient (API) particle-size control, and the application of flow modifiers to achieve predictable shear-thinning behaviour, rapid structural recovery, and homogeneous API distribution. Vital characteristics for a formulation to be extruded cleanly and then hold its shape once deposited. Physicochemical characterisation using techniques including HPLC, DSC, TGA, XRPD, and FTIR will facilitate formulation understanding and provides the evidence base for future developments.

The second objective targets hardware-driven improvements in extrusion consistency. Optimised nozzle geometries, enhanced thermal management, and the integration of pressure, torque, and temperature dynamics will be evaluated to minimise clogging, thermal gradients, and flow variability. Within this, a structured design-of-experiments (DOE) framework will link formulation attributes and hardware parameters to critical quality attributes, including dose uniformity, tablet geometry, mechanical strength, and dissolution performance. The anticipated practical outcomes include a validated operating space enabling higher throughput and enhanced quality of both feed material and print outcomes. In addition, practical guidelines for feedstock preparation and process control will have potential to inform future policy.

This research will provide the scientific and engineering foundations necessary to advance extrusion-based 3D printing toward reliable, GMP-compatible manufacturing of personalised oral medicines.

Overseas Applicants

Overseas applicants may apply for this studentship but will need to pay the difference between the ‘Home’ and the ‘Overseas’ tuition fees. Currently the difference between ‘Home’ and the ‘Overseas’ tuition fees is £17,712 for 2026/7. As part of the application, you will be required to confirm that you will provide this additional funding. Please indicate this on the application form in the funding section. This project has associated consumables costs which should be discussed with the supervisor in the first instance and before applying. The supervisor can be contacted at D.J.KIRBY1@aston.ac.uk. When applying, please upload copies of your discussions with the supervisor as confirmation.

Location

This position will be based on the Aston Campus in Birmingham, UK. The successful candidate will need to be located within a reasonable distance of the campus, and will be expected to visit in person regularly.

Person Specification

Candidates should have been awarded, or expect to achieve, EITHER:

a] a First or Upper Second Class award in their undergraduate degree, in a relevant subject.

OR

b] a First or Upper Second Class award in their undergraduate degree, and a Merit or Distinction in a Masters degree, both in a relevant subject.

Qualifications from overseas institutions will be considered, but performance must be equivalent to that described above, and the University reserves the right to ascertain this equivalence according to its own criteria.

Contact information

For formal enquiries about this project contact Dr Daniel Kirby at D.J.KIRBY1@aston.ac.uk

Submitting an application

We can only consider applications that are complete and have all supporting documents. Applications that do not provide all the relevant documents will be automatically rejected.Your application must include:

1. English language copies of the transcripts and certificates for all your higher education degrees, including any Bachelor degrees.
2. A Research Statement detailing your understanding of the research area, how you would approach the project, and a brief review of relevant literature. Be sure to use the title of the research project you are applying for. There is no set format or word count.
3. A personal statement which outlines any further information which you think is relevant to your application, such as your personal suitability for research, career aspirations, possible future research interests, and further description of relevant employment experience.
4. A Curriculum Vitae (Resume) which details your education and work history.
5. Two academic refereeswho can discuss your suitability for independent research. References must be on headed paper, signed and dated no more than 2 years old. At least one reference should be from your most recent University. You can submit your references at a later date if necessary.
6. Evidence that you meet the English Language requirements. If you do not currently meet the language requirements, you can submit this at a later stage.
7. A copy of your passport. Where relevant, include evidence of settled or pre-settled status.

Interviews

Interviews will be conducted online via Microsoft Teams. If you are shortlisted, you will be contacted directly with details of the interview.

Funding Notes

This project covers the Home tuition fees. Candidates who do not have Home status will be responsible for the difference in tuition fees. Currently the difference between ‘Home’ and the ‘Overseas’ tuition fees is £17,712 for 2026/7. This project has associated consumables costs which should be discussed with the supervisor in the first instance and before applying. The supervisor can be contacted at D.J.KIRBY1@aston.ac.uk. When applying, please upload copies of your discussions with the supervisor as confirmation.