Improving mRNA lipid nanoparticle preparation by testing different mixing methods and important factors

Streamlined S-channel designs and non-microfluidic methods can yield LNPs functionally equivalent in quality to complex staggered herringbone mixers.

• Microfluidic architectures, such as staggered herringbone and serpentine-only channels, influence lipid nanoparticle (LNP) size, stability, and transfection efficiency.
• Critical parameters, including total flow rate, flow rate ratio, and lipid-to-mRNA ratio, govern the characteristics of LNP formulations.
• In vivo assessments indicate that optimized formulations demonstrate systemic biocompatibility, maintaining stable physiological growth and organ function.
• No adverse histological changes or tissue damage were observed over an 8-week period.

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