Computational-Aided Approach for the Optimization of Microfluidic-Based Nanoparticles Manufacturing Process

In the last few years, the microfluidic production of nanoparticles (NPs) is becoming a promising alternative to conventional industrial approaches (e.g., nanoprecipitation, salting out, and emulsification-diffusion) thanks to the production efficiency, low variability, and high controllability of the production parameters. Nevertheless, the development of new formulations and the switching of the production process toward microfluidic platforms requires expensive and time-consuming number of experiments for the tuning of the formulation to obtain NPs with specific morphological and functional characteristics. In this work, we developed a computational fluid dynamic pipeline, validated through an ad hoc experimental strategy, to reproduce the mixing between the solvent and anti-solvent (i.e., acetonitrile and TRIS–HCl, respectively). Moreover, beyond the classical variables able to describe the mixing performances of the microfluidic chip, novel variables were described in order to assess the region of the NPs formation and the changing of the amplitude of the precipitation region according to different hydraulic conditions. The numerical approach proved to be able to capture a progressive reduction of the nanoprecipitation region due to an increment of the flow rate ratio; in parallel, through the experimental production, a progressive increment of the NPs size heterogeneity was observed with the same fluid dynamic conditions. Hence, the preliminary comparison between numerical and experimental evidence proved the effectiveness of the computational strategy to optimize the NPs manufacturing process.

Graphical Abstract