AccScience Publishing / MSAM / Online First / DOI: 10.36922/MSAM026230052
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ORIGINAL RESEARCH ARTICLE

Semisolid extrusion 3D-printed self-emulsifying β-sitosterol suppositories with structure-modulated release for potential rectal delivery

Xin Li1 Qingwen Song1,2 Luoru Chen1 Junfeng Ban1 Tao Zhu2 Peihong Chen1,3* Shu Zhang1*
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1 Guangdong Provincial Key Laboratory of Pharmaceutical Preparations Research and Evaluation, School of Pharmacy, Guangdong Pharmaceutical University, Guangzhou, Guangdong, China
2 Kmoeba (Zhuhai Hengqin) Biomedical Co., Ltd., Zhuhai, Guangdong, China
3 School of Biomedical and Pharmaceutical Sciences, Guangdong University of Technology, Guangzhou, Guangdong, China
Received: 2 June 2026 | Revised: 7 July 2026 | Accepted: 17 July 2026 | Published online: 19 August 2026
© 2026 by the Author(s). This article is an open access article distributed under the terms and conditions of the Creative Commons Attribution 4.0 International License ( https://creativecommons.org/licenses/by/4.0/ )
Abstract

Localized rectal delivery is a promising strategy for ulcerative colitis, as it may increase drug exposure at inflamed sites in the distal colorectum while reducing systemic exposure. However, many natural anti-inflammatory small molecules, including β-sitosterol, are hydrophobic and have poor aqueous dispersibility, limiting their formulation and therapeutic use. Conventional rectal dosage forms typically have fixed structures, making it difficult to tailor drug-release behavior. To address these challenges, a β-sitosterol-loaded self-emulsifying lipid suppository was fabricated using semisolid extrusion (SSE) three-dimensional (3D) printing, and the ability of the internal architecture to modulate early in vitro drug release was investigated. The Gelucire® 44/14-based matrix exhibited shear-thinning behavior and temperature-dependent softening, enabling SSE 3D printing. Upon contact with an aqueous medium, the printed suppositories formed submicron dispersions. Liquefaction and self-emulsification times ranged from 18.27 to 24.27 min and from 4.33 to 8.54 min, respectively. A representative formulation had a droplet size of 370.67 ± 39.09 nm and a polydispersity index of 0.27 ± 0.04. Fourier transform infrared, differential scanning calorimetry, and X-ray diffraction analyses indicated good drug–matrix compatibility and reduced β-sitosterol crystallinity, suggesting partial solubilization within the lipid matrix. With the matrix composition and external geometry held constant, in vitro release was adjusted by varying the internal pore architecture and nominal infill density. Lower-infill-density structures promoted faster medium penetration and earlier β-sitosterol release, whereas higher-infill-density structures slowed release by increasing structural resistance and diffusion-path tortuosity. These results demonstrate the feasibility of using SSE 3D printing to produce structure-modulated rectal dosage forms containing poorly water-soluble natural compounds.

Keywords
Semisolid extrusion
Three-dimensional printing
Ulcerative colitis
Self-emulsification
Suppository
Structure-modulated release
Funding
This project was supported by the Guangzhou Science and Technology Bureau project “Research on Screening of Superior Resources of Codonopsis pilosula and Development of Health Products” (2024B03J1322).
Conflict of interest
The authors declare that they have no known competing financial interests or personal relationships that could have appeared to influence the work reported in this paper.
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Materials Science in Additive Manufacturing, Electronic ISSN: 2810-9635 Published by AccScience Publishing