Microfluidic-based manufacture of siRNA-lipid nanoparticles for therapeutic applications.

A simple, efficient, and scalable manufacturing technique is required for developing siRNA-lipid nanoparticles (siRNA-LNP) for therapeutic applications. In this chapter we describe a novel microfluidic-based manufacturing process for the rapid manufacture of siRNA-LNP, together with protocols for characterizing the size, polydispersity, RNA encapsulation efficiency, RNA concentration, and total lipid concentration of the resultant nanoparticles.

Microfluidic integration of parallel solid-phase liquid chromatography.

We report the development of a fully integrated microfluidic chromatography system based on a recently developed column geometry that allows for robust packing of high-performance separation columns in poly(dimethylsiloxane) microfluidic devices having integrated valves made by multilayer soft lithography (MSL). The combination of parallel high-performance separation columns and on-chip plumbing was used to achieve a fully integrated system for on-chip chromatography, including all steps of automated sample loading, programmable gradient generation, separation, fluorescent detection, and sample recovery. We demonstrate this system in the separation of fluorescently labeled DNA and parallel purification of reverse transcription polymerase chain reaction (RT-PCR) amplified variable regions of mouse immunoglobulin genes using a strong anion exchange (AEX) resin. Parallel sample recovery in an immiscible oil stream offers the advantage of low sample dilution and high recovery rates. The ability to perform nucleic acid size selection and recovery on subnanogram samples of DNA holds promise for on-chip genomics applications including sequencing library preparation, cloning, and sample fractionation for diagnostics.

Fabrication of high-quality microfluidic solid-phase chromatography columns.

Here we report a low-pressure bead packing technique for the robust integration of high-performance chromatography columns in poly(dimethylsiloxane) microfluidic devices made by multilayer soft lithography (MSL). A novel column geometry featuring micrometer-sized bypass channels along the entire length of the separation channel is used to achieve rapid packing of multiple high-quality bead bed columns in parallel with near-perfect yield. Pulse tests show that these microfluidic columns achieve exceptional reproducibility and efficiency, with measured plate counts of 1,650,000/m ± 7%, corresponding to a reduced plate height of h = 0.12 ± 7%. The combination of high-performance chromatography columns and valve-based microfluidics offers new opportunities for the integration of sample processing with preparative and analytical separations for biology and chemistry.

Bottom-up design and synthesis of limit size lipid nanoparticle systems with aqueous and triglyceride cores using millisecond microfluidic mixing.

Limit size systems are defined as the smallest achievable aggregates compatible with the packing of the molecular constituents in a defined and energetically stable structure. Here we report the use of rapid microfluidic mixing for the controlled synthesis of two types of limit size lipid nanoparticle (LNP) systems, having either polar or nonpolar cores. Specifically, limit size LNP consisting of 1-palmitoyl, 2-oleoyl phosphatidylcholine (POPC), cholesterol and the triglyceride triolein were synthesized by mixing a stream of ethanol containing dissolved lipid with an aqueous stream, employing a staggered herringbone micromixer. Millisecond mixing of aqueous and ethanol streams at high flow rate ratios (FRR) was used to rapidly increase the polarity of the medium, driving bottom-up synthesis of limit size LNP systems by spontaneous assembly. For POPC/triolein systems the limit size structures consisted of a hydrophobic core of triolein surrounded by a monolayer of POPC where the diameter could be rationally engineered over the range 20-80 nm by varying the POPC/triolein ratio. In the case of POPC and POPC/cholesterol (55/45; mol/mol) the limit size systems achieved were bilayer vesicles of approximately 20 and 40 nm diameter, respectively. We further show that doxorubicin, a representative weak base drug, can be efficiently loaded and retained in limit size POPC LNP, establishing potential utility as drug delivery systems. To our knowledge this is the first report of stable triglyceride emulsions in the 20-50 nm size range, and the first time vesicular systems in the 20-50 nm size range have been generated by a scalable manufacturing method. These results establish microfluidic mixing as a powerful and general approach to access novel LNP systems, with both polar or nonpolar core structures, in the sub-100 nm size range.

Microfluidic Synthesis of Highly Potent Limit-size Lipid Nanoparticles for In Vivo Delivery of siRNA.

Lipid nanoparticles (LNP) are the leading systems for in vivo delivery of small interfering RNA (siRNA) for therapeutic applications. Formulation of LNP siRNA systems requires rapid mixing of solutions containing cationic lipid with solutions containing siRNA. Current formulation procedures employ macroscopic mixing processes to produce systems 70-nm diameter or larger that have variable siRNA encapsulation efficiency, homogeneity, and reproducibility. Here, we show that microfluidic mixing techniques, which permit millisecond mixing at the nanoliter scale, can reproducibly generate limit size LNP siRNA systems 20 nm and larger with essentially complete encapsulation of siRNA over a wide range of conditions with polydispersity indexes as low as 0.02. Optimized LNP siRNA systems produced by microfluidic mixing achieved 50% target gene silencing in hepatocytes at a dose level of 10 µg/kg siRNA in mice. We anticipate that microfluidic mixing, a precisely controlled and readily scalable technique, will become the preferred method for formulation of LNP siRNA delivery systems.

Three-dimensional large-scale microfluidic integration by laser ablation of interlayer connections.

Multilayer Soft Lithography (MSL) is a robust and mature fabrication technique for the rapid prototyping of microfluidic circuits having thousands of integrated valves. Despite the success and wide application of this method, it is fundamentally a planar fabrication technique which imposes serious design constraints on channel routing, feature density, and fluid handling complexity. We present here methods and related instrumentation to remove these limitations by combining the advantages of MSL processing with laser micromachining using a CO(2) laser ablation system. This system is applied to both the dense integration of layer-layer interconnects and the direct writing of microchannels. Real-time image recognition and computer control allow for robust wafer-scale registration of laser ablation features with moulded channel structures. Ablation rates of up to 8 Hz are achieved with positional accuracy of approximately 20 microm independent of mechanical distortions in the elastomer substrate. We demonstrate these capabilities in the design and fabrication of a production scale multi-laminate micromixer that achieves sub-millisecond mixing of two streams at flow rates up to 1 mL min(-1). The marriage of laser micromachining with MSL-based valve integration allows for high-yield fabrication of topologically complex microfluidic circuits having thousands of layer-layer interconnects and integrated valves.