Microfluidics‐Based Nanoparticle Formulations: Preparation and Evaluation of Protein Delivery Systems

ABSTRACT Polymeric nanoparticles have attracted significant attention due to their potential in drug delivery, material science, and chemistry. In general, the targeted activities of nanoparticles (NPs) are affected by their size and morphology. Microfluidic methods offer precise control over nanoparticle properties, providing better reproducibility and uniformity. This study investigates the effects of microfluidic method parameters on the physicochemical properties and protein delivery potential of synthesized poly(lactic‐co‐glycolic acid) (PLGA) nanoparticles. The size of the nanoparticles was precisely tuned by varying the flow rate ratios (FRR), total flow rate (TFR), polymer, protein, and surfactant concentrations. Proteins with various molecular weights, including bovine serum albumin (BSA), lysozyme, and aprotinin, were effectively encapsulated, and their drug release kinetics and structural integrity were investigated. By simultaneously evaluating three structurally distinct model proteins within a single microfluidic system, this study provides a comprehensive insight into the role of protein size and charge on nanoparticle formation and release behavior for the first time. This research contributes to the advancement of nanoparticle formulation strategies using microfluidic technology. Microfluidic systems hold great potential for rapid, easy, effective, low‐cost, and high‐yield NP production.