Continuous manufacturing of nanomedicines using 3D-printed microfluidic devices

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Kara, Aytug and Ongoren, Baris and Anaya Meza, Bryan Javier and Serrano, Dolores R. and Lalatsa, Katerina (2025) Continuous manufacturing of nanomedicines using 3D-printed microfluidic devices. Applied Materials Today. ISSN 2352-9407 (In Press)

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Abstract

Microfluidic technologies have emerged as a promising strategy, utilizing nano and microscale manufacturing devices to create highly controllable and reproducible fluid microenvironments. These technologies have enormous potential in various applications, including drug delivery systems, diagnostics, and tissue engineering. Developing nanomedicines, which can provide targeted and controlled drug release with minimal side effects, is an appealing application. Until now, microfluidic devices have been manufactured using glass or polydimethylsiloxane (PDMS) materials based on soft lithography or microinjection molding technology. However, 3D printing has arisen as an advanced novel technique capable of manufacturing microfluidic devices. 3D printing, also known as additive manufacturing, deposits materials layer by layer to create complex structures with high precision and accuracy. Rapid prototyping, customization, and low-cost production are all advantages of this manufacturing technique in producing microfluidic devices. Recent advances in 3D printing have enabled the fabrication of intricately designed microfluidic chips, resulting in improved functionality and performance for tuning nanoparticle size, and drug loading allowing more precise fluid flow and mixing control, less material waste, and improved reproducibility. Combining 3D-printed microfluidic chips with other industrial, scalable drying technologies, such as spray coating and spray drying, can bridge the gap in the continuous manufacturing of nanomedicines. This review will focus on the role of 3D printing in creating microfluidic devices, its capability to fabricate nanomedicines in a single batch, and the implementation of continuous manufacturing methodologies for reproducibility at an industrial scale. The combination of microfluidics and 3D printing provides a promising avenue for developing and producing novel nanomedicines that can revolutionize manufacturing strategies and improve patient outcomes.

ORCID iDs

Kara, Aytug, Ongoren, Baris, Anaya Meza, Bryan Javier, Serrano, Dolores R. and Lalatsa, Katerina ORCID logoORCID: https://orcid.org/0000-0003-4791-7468;
CORE (COnnecting REpositories)