Orodispersible films as multifunctional drug delivery systems: From conventional formulations to digital manufacturing

Orodispersible films (ODFs) have emerged as an innovative and patient-friendly drug delivery platform that rapidly disintegrates in the oral cavity without the need for water, offering significant advantages over conventional oral dosage forms. ODF technology is particularly beneficial for pediatric, geriatric, dysphagic, and psychiatric patients who experience difficulty swallowing tablets and capsules. The present review provides a comprehensive overview of the fundamental principles, classification, mechanisms, formulation strategies, and therapeutic applications of ODFs. Special emphasis is placed on the role of excipients, including film-forming polymers, plasticizers, sweeteners, and permeation enhancers, in determining the mechanical properties, disintegration behavior, and drug release characteristics of the films. Various manufacturing approaches, such as solvent casting, hot-melt extrusion, electrospinning, rolling methods, and advanced printing technologies, are critically discussed with respect to their advantages and limitations. Furthermore, currently marketed ODF products and their therapeutic indications are summarized to highlight the growing commercial relevance of this dosage form. Recent advances in nanotechnology, biologics delivery, and personalized medicine have expanded the potential applications of ODFs, positioning them as promising platforms for precision drug delivery. Owing to their rapid onset of action, enhanced bioavailability, improved patient compliance, and adaptability to modern pharmaceutical technologies, orodispersible films represent a significant advancement in oral drug delivery systems and hold considerable promise for future therapeutic innovations.