A new study co-authored by Nick Allan, StarFish Medical Bio Services Manager, and published in Scientific Reports highlights how device design can make or break intranasal RNA delivery. The research compares three delivery systems for lipid nanoparticle (LNP)-formulated RNA vaccines: a commercial nebulizer, a commercial spray, and a novel laminar fluid ejection (LFE) device.

The findings are striking. Devices that use high-shear forces, like vibrating mesh nebulizers, significantly degraded RNA payloads, increased particle size, and lowered encapsulation efficiency. In contrast, the LFE device preserved the structure and function of both mRNA and self-amplifying RNA (saRNA), maintaining encapsulation efficiency as high as 94% for mRNA and 102% for saRNA. This led to the highest levels of functional protein expression in transfected cells—up to three times more than the commercial nebulizer.

By delivering RNA-LNP formulations gently through laminar flow, the LFE device minimizes mechanical stress while maximizing payload integrity and biological performance. These characteristics are critical for next-generation mucosal RNA vaccines, where intranasal delivery must strike a balance between efficacy and safety.

The study also underscores the importance of selecting the right delivery method when designing RNA-based intranasal therapeutics. As vaccines and therapies continue to evolve beyond traditional injectables, device engineering will play an increasingly pivotal role in therapeutic performance and patient experience.

For developers of respiratory vaccines, saRNA platforms, and intranasal biologics, this paper offers practical guidance and strong evidence that intranasal RNA delivery can be made both efficient and effective—if the delivery method is optimized.