The manufacturing of 3D-printed microfluidic chips to analyse the effect upon particle size during the synthesis of lipid nanoparticles

Objectives The process of 3D printing to produce microfluidic chips is becoming commonplace, due to its quality, versatility and newfound availability. In this study, a UV liquid crystal display (LCD) printer has been implemented to produce a progression of microfluidic chips for the purpose of liposomal synthesis. The emphasis of this research is to test the limitations of UV LCD printing in terms of resolution and print speed optimisation for the production of microfluidic chips. Key findings By varying individual channel parameters such as channel length and internal geometries, the essential channel properties for optimal liposomal formulation are being investigated to act as a basis for future experimentation including the encapsulation of active pharmaceutical ingredients. Using the uniquely designed chips, liposomes of approximate to 120 nm, with polydispersity index values of <= 0.12 are able to be reproducibly synthesised. Conclusions The influence of total flow rates and lipid choice is investigated in depth, to provide further clarification on how a microfluidic setup should be optimised. In-depth explanations of the importance of each channel parameter are also explained throughout, with reference to their importance for the properties of a successful liposome.

Automated summary

In this study, a UV LCD printer was used to produce microfluidic chips for liposomal synthesis, and the limitations of UV LCD printing in terms of resolution and print speed optimization were tested. By varying channel parameters, the essential properties for optimal liposomal formulation were investigated, and liposomes with sizes of approximately 120 nm and polydispersity index values of <= 0.12 were successfully synthesized. The influence of total flow rates and lipid choice on microfluidic setup optimization was also investigated in depth.