Perfluorocarbon-loaded
nanoparticles are powerful theranostic agents, which are used in the
therapy of cancer and stroke and as imaging agents for ultrasound
and
19
F magnetic resonance imaging (MRI). Scaling up the
production of perfluorocarbon-loaded nanoparticles is essential for
clinical translation. However, it represents a major challenge as
perfluorocarbons are hydrophobic and lipophobic. We developed a method
for continuous-flow production of perfluorocarbon-loaded poly(lactic-
co
-glycolic acid) (PLGA) nanoparticles using a modular microfluidic
system, with sufficient yields for clinical use. We combined two slit
interdigital micromixers with a sonication flow cell to achieve efficient
mixing of three phases: liquid perfluorocarbon, PLGA in organic solvent,
and aqueous surfactant solution. The production rate was at least
30 times higher than with the conventional formulation. The characteristics
of nanoparticles can be adjusted by changing the flow rates and type
of solvent, resulting in a high PFC loading of 20–60 wt % and
radii below 200 nm. The nanoparticles are nontoxic, suitable for
19
F MRI and ultrasound imaging, and can dissolve oxygen.
In vivo
19
F MRI with perfluoro-15-crown-5 ether-loaded
nanoparticles showed similar biodistribution as nanoparticles made
with the conventional method and a fast clearance from the organs.
Overall, we developed a continuous, modular method for scaled-up production
of perfluorocarbon-loaded nanoparticles that can be potentially adapted
for the production of other multiphase systems. Thus, it will facilitate
the clinical translation of theranostic agents in the future.