This work presents a novel 3D-printed microfluidic Tesla mixer designed with cone-shaped obstructions to dramatically enhance mixing efficiency for nanoparticle formulation. Through computational modeling and experimental validation, the device achieved near-complete mixing within milliseconds, enabling the controlled synthesis of small, uniform poly(lactic-co-glycolic acid) (PLGA) nanoparticles. By optimizing flow conditions, polymer concentration, and solvent selection, the researchers demonstrated that the Tesla mixer provides far superior nanoparticle uniformity compared to conventional bulk mixing, while also avoiding common issues such as aggregation and clogging.

Most importantly, the system enabled exceptional encapsulation of curcumin into PLGA nanoparticles, achieving encapsulation efficiencies up to 68.4% and drug loading up to 43.0%, far surpassing traditional methods. The resulting nanoparticles exhibited sustained and pH-responsive release profiles, confirming their potential as effective drug delivery vehicles. With its scalable design and compatibility with 3D printing, the 3D Tesla mixer represents a promising platform for producing high-quality nanomedicines, not only for curcumin but also for a wide range of therapeutic compounds.