Nanosizing has emerged as one of
the most effective formulation
strategies for enhancement of dissolution properties of active pharmaceutical
ingredients (APIs). In addition to enhancing the specific area of
the dissolving solids, nanosizing can also capture and stabilize the
metastable form of the API, which can further enhance the solubility
by drastic modulation of surface energies. Herein, we employ meniscus-guided
coating to fabricate nanothin films of three APIs that show anticancer
properties and are poorly soluble:10-HCPT, SN-38, and amonafide. By
modulating the coating speed, we systematically deposited the APIs
in films ranging from ∼200 nm thickness to extreme confinement
of ∼10 nm (<10 molecular layers). In all three APIs, we
observe a general order-to-disorder transition with semicrystalline
(10-HCPT and amonafide) or amorphous (SN-38) form of API solids trapped
in thin films when the thickness decreases below a critical value
of ∼25–30 nm. The existence of a critical thickness
highlights the importance of nanoconfinement in tuning molecular packing.
In the case of 10-HCPT, we demonstrate that the disordered form of
the API occurs largely due to lack of incorporation of water molecules
in thinner films below the critical thickness, thereby disrupting
the three-dimensional hydrogen-bonded network held by water molecules.
We further developed a dissolution model that predicts variation of
the intrinsic dissolution rate (IDR) with API film thickness, which
also closely matched with experimental results. We achieved drastic
improvement in the IDR of ∼240% in 10-HCPT by decreasing film
thickness alone. Further leveraging the order-to-disorder transition
led to 2570% modulation of the IDR for amonafide. Our work demonstrates,
for the first time, opportunities to largely modulate API dissolution
by precisely controlling the dimensionality of thin films.