A comparison between solvent casting and electrospinning methods for the fabrication of HPMC fast-dissolving films: investigation of the physicochemical, mechanical and drug release characteristics

Abstract The fast-dissolving film is an innovative dosage form that rapidly delivers the loaded drug upon contact with saliva. Many studies have been conducted on the fabrication of fast-dissolving films using hydroxy propyl methyl cellulose (HPMC) as a common film-forming agent with solvent-casting method or sometimes with electrospinning. However, there is no comparison of these two methods on the physicochemical, mechanical, and drug-release behavior of HPMC films. This paper aims to compare bisoprolol-containing fast-dissolving films composed of HPMC and polyethylene glycol (PEG) as plasticizer constructed by solvent-casting and electrospinning methods. Given the formulation parameters (e.g., plasticizer and polymer concentrations) and process parameters (e.g., tip-to-needle distance, voltage, and feed rate), various solvent-casting films and nanofiber mats were prepared. Films were characterized in terms of disintegration time, folding endurance, thermal behavior (using DSC), crystallin structure (using XRD), drug content, and drug release. The size and morphology of nanofibers were also evaluated by SEM. Solvent-casting film composed of 6% w/v HPMC and 6% v/v PEG400, as well as nanofiber mat composed of 13% w/v HPMC and 3% w/v PEG2000 were successfully constructed. DSC and XRD analysis revealed that the crystalline structure of bisoprolol converted into the amorphous structure in the polymeric films. Nanofibers were smooth and free of beads with a mean size of 0.66 ± 0.19 μ m. In terms of flexibility, the nanofiber mats outperformed the solvent-casting films. The disintegration time of the nanofiber mat was less than that of the solvent-casting film (3 s versus 30 s). Besides, nanofibers indicated faster release. The superior performance of nanofiber mats can be attributed to their nanostructure. The results showed that the characteristics of the fast-dissolving films fabricated of HPMC, including disintegration time, release rate, and flexibility could be improved through the electrospinning process.