Affordable, cleanroom-free millifluidic production of targeted lipid nanocarriers via additive manufacturing

Abstract

Lipid nanocarriers utilise the self-assembly of amphiphilic molecules to generate particle formulations capable of drug encapsulation and dynamic interactions with user-defined cell types, enabling applications within targeted therapeutic delivery. This offers increased bioavailability, stability, and reduced off-target effects, with the promise of application to numerous cell types and consequently, diseases. Here, we have developed a highly accessible, cleanroom-free method for the fabrication of poly(methyl methacrylate) millifluidic vertical flow focusing (VFF) devices via laser cutting, multilayered solvent and heat-assisted bonding. We demonstrate that these can be used for one-step production of targeted lipid nanocarriers via the production of cardiomyocyte-targeting vesicle nanoparticles loaded with the hydrophobic drug menadione. We characterise vesicle size using dynamic light scattering (DLS) and cryogenic transmission electron microscopy (cryo-TEM), whilst also probing the membrane viscosity of vesicles produced via flow-focusing for the first time using molecular rotors. Finally, we apply cardiomyocyte-targeting, menadione-loaded vesicles to H9C2 tissue culture demonstrating significant inhibition of cell viability via targeted delivery, showcasing the potential of our device to produce formulations for therapeutic delivery. As a flow-based method, VFF can facilitate rapid formulation investigation and produce large sample volumes for cell-based validation studies, whilst avoiding inter-batch sample variation. Furthermore, the accessible nature of this VFF approach will help to democratise millifluidics, facilitating the wider adoption of flow-based production methods to develop nanomedical formulations.