Fast-dissolving electrospun cellulose fiber-based matrices as modular oral dosage forms

Fast-dissolving oral dosage forms are attractive systems for controlled delivery of poorly water-soluble drugs. This study introduces a novel modular oral dosage platform composed of fast-dissolving drug-loaded electrospun hydroxypropyl methylcellulose (HPMC)/ polyethylene oxide (PEO) fibers. Electrospun fibers were fabricated and optimized using two solvent systems, namely dichloromethane/ethanol and water/ethanol, and loaded with model compounds exhibiting different solubility profiles. Characterization by scanning electron microscopy, differential scanning calorimetry, and X-ray diffraction confirmed the formation of drug-loaded HPMC/PEO-based fibers with drug amorphization. Dissolution studies of as-fabricated fibers demonstrated rapid disintegration and efficient drug release from the fibers. An optimized fabrication process was further developed to form a proof-of-concept integrated bilayer module by enabling the precise deposition of drug-loaded electrospun fibers onto a solvent-cast non-drug-loaded HPMC-based film. The fibrous layer maintained its bead-free morphology, reduced crystallinity, and fast dissolution properties post-integration. Our findings highlight the potential of drug-loaded electrospun HPMC/PEO fibers as an advanced drug delivery system, supporting the development of next-generation modular oral dosage forms for controlled and customizable drug delivery.