Scalable Multistage Microfluidic Platform for One-Pot Synthesis and Optimization of Drug-Loaded Magnetic Nanoparticles in Cancer Treatment Publisher



Vaziri M ; Ahmadi H ; Kamankesh M ; Taghipoor M ; Tabatabaei N ; Ghahremani MH ; Akrami M ; Handali S ; Dorkoosh FA
Source: Journal of Industrial and Engineering Chemistry Published:2026

Abstract

Multifunctional nanocarriers, particularly magnetic nanoparticles (MNPs), have gained significant attention due to their ability to enhance targeted drug delivery, enable controlled drug release, and respond to external stimuli for improved therapeutic efficacy. However, achieving a high-throughput one-step method that ensures uniformity, reproducibility, and high stability of MNPs while improving surface coating efficiency and drug loading remains challenging. Here, we developed an integrated multistage microfluidic chip with lamination-based split-and-recombine 3D micromixers as an efficient platform for the preparation of chitosan-coated MNPs containing Gemcitabine. Response Surface Methodology (RSM) was employed to optimize synthesis conditions. To assess the proposed platform, microfluidic synthesized MNPs (MMNPs) were compared in various aspects with the conventional batch flow method (BMNPs). MMNPs had a particle size of 104.3 ± 15.34 nm with an encapsulation efficiency (EE) of 81.3 ± 1.6 %, whereas BMNPs demonstrated a larger particle size of 172.8 ± 35.33 nm and an EE of 39.6 ± 2.1 %. Additional advantages include reduced synthesis time, elimination of inert gas requirements, and improved polydispersity index, leading to scalable, high-quality NP production. This microfluidic approach provides a rapid, resource-efficient method for producing multifunctional NPs, offering significant potential for advanced cancer therapy and broader nanomedicine applications. © 2025 The Korean Society of Industrial and Engineering Chemistry.