Evaluation of rayleigh jet atomizer for intranasal delivery of lipid nanoparticle-siRNA formulations: stability, deposition, and device performance

The COVID-19 pandemic has emphasised the need for innovative and efficient drug delivery systems, particularly for nucleic acid-based therapeutics. Lipid nanoparticle (LNP)-based small interfering RNA (siRNA) technology provides a promising strategy for gene therapy, immune modulation, and targeted molecular medicine. Intranasal delivery of LNP-siRNA formulations offers advantages such as efficient gene silencing and non-invasive administration. However, the nasal spray device plays a crucial role in determining the deposition patterns within the nasal cavity and can impact the physicochemical stability of LNP formulations during aerosolisation. In this study, the Rayleigh Jet Nasal Atomizer was evaluated for its performance in delivering three LNP-siRNA formulations designed based on the LNP structures of Moderna, Pfizer, and Alnylam (Onpattro) marketed formulations, respectively. Key nanoparticle characteristics, including particle size distribution, polydispersity index (PDI), zeta potential, and encapsulation efficiency, as well as aerosol properties such as droplet size, were analyzed before and after aerosolisation. Deposition patterns were assessed using the Alberta Idealized Nasal Inlet (AINI) model to determine the distribution of aerosolized LNPs. The results demonstrate that the Rayleigh Jet Nasal Atomizer efficiently delivers all the three formulations to the nasal cavity, primarily targeting the nasopharynx, while minimizing deposition in the lower respiratory tract. Additionally, the device maintained LNPs structural integrity, although a reduction in encapsulated siRNA concentration suggests partial LNP disruption during aerosolisation. These findings indicate that the Rayleigh Jet Nasal Atomizer is a suitable device for intranasal delivery of LNP-based siRNA therapeutics, offering a promising approach for nasal administration of RNA-based drug delivery.