In a groundbreaking advancement in cancer treatment, engineers at MIT have developed a novel method for mass-producing nanoparticles coated with therapeutic drugs. These cutting-edge polymer-coated nanoparticles have shown significant effectiveness in targeting tumors, particularly ovarian cancer, and offer a promising alternative to traditional chemotherapy by minimizing harmful side effects.

For over a decade, MIT's Institute Professor Paula Hammond and her dedicated team have pioneered a technique known as layer-by-layer assembly, which allows for the precise construction of these nanoparticles. They have conducted extensive research demonstrating the particles' potent anti-cancer properties in mouse models, paving the way for potential human applications.

To transition from laboratory research to real-world clinical use, the MIT researchers have successfully created an innovative manufacturing process that significantly enhances scalability and efficiency. This breakthrough is critical, as high-throughput manufacturing is essential for providing sufficient quantities of nanoparticles for extensive clinical trials and eventual patient treatment.

“There’s immense potential with the nanoparticle systems we've been developing, especially in the context of ovarian cancer trials,” explains Hammond, also serving as MIT's vice provost for faculty and a member of the Koch Institute for Integrative Cancer Research. “We aim to refine this technology to allow for large-scale production in a commercially feasible manner.”

Streamlined Production Process

Hammond's laboratory initially developed a process that layers differing properties on nanoparticles using alternating positively and negatively charged polymers. While this method was effective, it required a time-intensive purification step after each layer was applied, which was not ideal for large-scale production.

Recently, a graduate student introduced tangential flow filtration, simplifying purification but still hampered by production limitations. To tackle these challenges, the team engineered a microfluidic mixing device, allowing for the continuous flow and layered addition of polymers directly on the nanoparticles, eliminating the need for post-layer purification.

This innovation not only reduces production costs and time but also integrates robust manufacturing practices that comply with FDA regulations, ensuring safety and consistency in the production process. With this microfluidic device, which has been previously utilized for manufacturing other nanoparticles such as mRNA vaccines, the researchers can significantly enhance the efficiency of nanoparticle production.

Accelerated Manufacturing

Thanks to this new method, researchers can produce 15 milligrams of nanoparticles—equivalent to approximately 50 treatment doses—in mere minutes, compared to the original hour-long process. This rapid production capability is vital for advancing the technology into human trials.

The research team showcased their method by creating nanoparticles imbued with interleukin-12 (IL-12), a cytokine previously shown to activate crucial immune responses against tumors in animal studies. Notably, these nanoparticles not only bind to cancerous tissues but also avoid penetrating cancer cells, effectively serving as markers that stimulate localized immune activity within the tumor.

Findings from their studies revealed that IL-12-loaded nanoparticles produced using this innovative technique demonstrated comparable efficacy to those made with the traditional method, offering hope for substantial tumor growth delays—even the potential for cures—in preclinical models of ovarian cancer.

The researchers have filed for a patent to protect this promising technology and are in collaboration with MIT's Deshpande Center for Technological Innovation to explore commercial opportunities. While the initial focus is on abdominal cancers like ovarian cancer, the technology holds promise for broader applications, potentially benefiting patients with other challenging cancers, such as glioblastoma.

This remarkable effort to revolutionize cancer treatment exemplifies the intersection of advanced materials science and medicine, fostering hope for a future where targeted therapies become standard practice in oncological care.