Microfluidic manufacturing of advanced gene delivery
vectors necessitates
consideration of the effects of microfluidic shear forces on the structural
integrity of plasmid DNA (pDNA). In this paper, we expose pDNA to
variable shear forces in a two-phase, gas–liquid microfluidic
reactor and apply gel electrophoresis to analyze the products of on-chip
shear-induced degradation. The effects of shear rate, solvent environment,
pDNA size, and copolymer complexation on shear-induced degradation
are investigated. We find that small naked pDNA (pUC18, 2.7 kb) exhibits
shear rate-dependent shear degradation in the microfluidic channels
in a mixed organic solvent (dioxane/water/acetic acid; 90/10/<0.1
w/w/w), with the extents of both supercoil isoform relaxation and
complete fragmentation increasing as the maximum shear rates increase
from 4 × 105 to 2 × 106 s–1. However, over the same range of shear rates, the same pDNA sample
shows no evidence of microfluidic shear-induced degradation in a pure
aqueous environment. Quiescent control experiments in the same mixed
organic solvent prove that a combination of solvent and shear forces
is involved in the observed shear-induced degradation. Furthermore,
we show that shear degradation effects in mixed organic solvents can
be significantly attenuated by complexation of pDNA with the block
copolymer polycaprolactone-block-poly(2-vinylpyridine)
prior to exposure to microfluidic shear. Finally, we demonstrate that
medium (pDSK519, 8.1 kb) and large (pRK290, 20 kb) naked pDNA are
more sensitive to shear-induced microfluidic degradation in the mixed
organic solvent environment than small pDNA, with both plasmids showing
complete fragmentation even at the lowest shear rate, although we
found no evidence of shear-induced damage in water for the largest
investigated naked pDNA even at the highest flow rate. The resulting
understanding of the interplay of the solvent and shear effects during
microfluidic processing should inform microfluidic manufacturing routes
to new gene therapy formulations.