ArticleSmall (Weinheim an der Bergstrasse, Germany)2026
3D-Printed Milli-Fluidic Mixing-Extrusion Platform for Continuous, High-Throughput LNP Production.
Article in Small (Weinheim an der Bergstrasse, Germany), 2026. The graph could read no effect estimate from its abstract, so it casts no vote on the map. Not yet cited in PubMed.
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7 authors.
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Abstract
Lipid nanoparticles (LNPs) have emerged as a prominent delivery vehicle for therapeutics such as mRNA vaccines and genetic medicines. However, current manufacturing technologies struggle to balance precision, scalability, and cost-effectiveness. While microfluidic mixing offers excellent particle control, it often faces operational challenges, including channel fouling and a reliance on costly single-use chips that create bottlenecks for reproducible and scalable production of LNPs. Conversely, bulk methods lack uniformity, and conventional extrusion remains a labor-intensive batch process. Here, we report a hybrid continuous synthesis platform that integrates a reusable 3D-printed milli-fluidic mixer with inline membrane extrusion. By engineering a robust 3D internal architecture at the milli-scale, this system achieves rapid mixing while mitigating clogging risks associated with micro-channels. Our platform also offers a durable, easy-to-clean alternative that enhances process reproducibility while the integrated design enables single-pass refinement of LNPs, streamlining the production workflow to achieve high-quality, uniform LNPs at flow rates of up to 20 mL min
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