The leaf extract from Tithonia diversifolia is recognized for its ability to deter feeding in various Lepidoptera insect pests, including the larvae of Crocidolomia pavonana. Presently, transformation efforts from conventional formulations into nano-based formulations for biopesticides exhibit enhanced effectiveness and efficiency. Utilizing a low-energy process, an inversion emulsion facilitates the dispersion of the extract suspension in an organic solvent into a water-immiscible solvent using a suitable surfactant. The forming nano-size droplets in water (t1, t2, t3, t4) are influenced by the ratio of surfactant and organic suspension (Water: Tween 80: Organic suspension). The emulsification method successfully formulated T. diversifolia leaf extract, into dispersed nano-size and submicron suspensions in water. The t3 formula exhibits the smallest nano-size dispersed in water (D=23.6 ± 39.6 nm; polydispersity index IP=0.702) and enhanced wettability, evident in the lower contact angle of the droplet on the cabbage leaf surface (49.4°) compare with the control group. The Phytochemicals confirmed by IR-spectra analysis identified the phenols, alkaloids, and steroids constituents of leaf extract, which are known to have antifeedant properties. The enhanced antifeedant properties of T. diversifolia nanosuspension against C. pavonana third-instar larvae demonstrated by the antifeedant test results showing that t3 is the most successful deterrent larvae feeding activity compared to the control (P<0.05), due to the highest total antifeedant coefficient (74.27%) in a category medium antifeedant activity, while the non-emulsification displayed the lowest antifeedant coefficient (25.36%) in a category as low antifeedant activity. T. diversifolia leaf extract with a nano-based formula succeeded resulting in dispersed nano-size and submicron suspension in aqueous media, thereby reducing surface tension and enhancing wettability on the leaf surface during application. The improved dispersion of antifeedant nanosuspension on the leaf surface results in more effective delivery to target insects.