In the realm of drug delivery, particularly for cancer therapeutics, there is a growing demand for robust nanocarrier systems that offer improved targeting, extended shelf-life, and consistent efficacy. Liposomes have historically served as biocompatible delivery vehicles; however, they often suffer from formulation instability and limited storage viability. As pharmaceutical pipelines increasingly depend on nanoparticle-based delivery systems, the need to overcome limitations in processing and stability becomes increasingly urgent.
Current fabrication methods—such as probe sonication and high-shear mixing—introduce significant physical stress during nanoparticle formation. These processes frequently disrupt vesicle structure, leading to drug leakage, unpredictable size distributions, and compromised performance. Moreover, such techniques are difficult to scale reproducibly, posing major barriers for clinical translation and commercial manufacturing. A low-shear, scalable alternative is needed to preserve liposomal integrity while supporting controlled, reproducible drug delivery.
This technology leverages a 3D printing approach known as Sprayed Multi-Adsorbed Droplet Reposing Technology (SMART) to create proliposomes—solid precursors that form liposomes upon hydration. A precisely engineered mixture of phospholipid, cholesterol, surfactant, cyclodextrin, and drug is dissolved in ethanol and printed via a 27G nozzle at controlled pressures and speeds onto a heated surface. The printed product is subsequently freeze-dried, producing stable nanostructures with enhanced storage potential and reconstitution properties.
SMART printing eliminates the need for damaging high-energy processes by minimizing shear during fabrication. The resulting proliposomes exhibit a hydrophilic exterior and lipophilic core, allowing efficient encapsulation of active agents and improved passive targeting via enhanced permeability and retention (EPR). Characterization confirms uniform size distribution, low polydispersity index, favorable cytocompatibility, and sustained drug release. This innovation offers a one-step, scalable method for fabricating next-generation nanocarriers for cancer treatment.