LNP-based delivery systems are predominantly utilized for intravenous, subcutaneous, and intramuscular injections. In the case of LNPs-enabled RNA vaccines, a tightly regulated cold chain infrastructure is necessary
118—123. Parenteral formulations face further hurdles, such as the instability of liquid formulations at ambient temperatures, the need for skilled healthcare personnel, patient reluctance towards this delivery method (due to needle phobia, injection site pain, and risks of unintended local or systemic immune responses), and the potential for contamination (related to needle or injection site). These challenges have been thoroughly examined in previous studies
124. Some of these challenges could be overcome by changing to a dry powder formulation suitable for inhalation. Friis et al.
125 described a proof-of-concept study on engineering an mRNA-LNPs formulation suitable for spray drying. This process produced a dry powder formulation that maintained stability and preserved mRNA functionality with increased performance compared to liquid formulations stored for two weeks at 4 °C. The spray-dried LNPs may be used in future research for inhalation or intratracheal delivery systems. The process is illustrated in
Fig. 4A. As current clinical formulations are not optimized for lung inhalation, effectively addressing the complex pulmonary vaccine landscape necessitates a meticulous reassessment of mRNA formulation strategies that can enhance stability and prolong shelf life. Among other methods, we summarized the most recently published studies on the use of mRNA-LNPs in inhaled delivery systems. They have made a series of optimizations to improve LNPs inhalation delivery. These were then categorized into the following five aspects: LNPs formulation, excipient addition, inhalation buffer, electrostatic repulsions, PEG concentration, and cholesterol analog. The properties of inhaled LNP, both structural and biological, can be attributed to a single factor and the optimal combination(
Fig. 4B)
34,39. Both Dahlman and Anderson analyzed prescription screening for the components of inhaled LNPs. Fortunately, Lokugamage and coworkers
34 revealed the development strategy for inhalation therapy in their research. The employment of 7Cl lipid caused the 28-fold difference in delivery between the best- and worst-performing LNPs simply by changing the formulation ratio. In addition, the team proposed three principles for inhaled LNPs delivery systems: (1) PEG-lipids were essential for forming stable 7C1-based LNPs structures. (2) Combining cation-assisted lipids and a high molar percentage of PEG resulted in increased mRNA delivery after inhalation. (3) LNPs formulated with neutral phospholipid lipids required less PEG than cation-assisted lipids. Based on these three principles, the research team constructed an LNP called Nebulized Lung Delivery 1 (NLD1) for further analysis. By comparing the relative size of different dynamic light scattering peaks, the researchers found that NLD1 was more stable than cKK-E12 and MC3. Finally, NLD1 was stable and well tolerated after inhalation, and the lung transfection efficiency was higher. The lung intensively expressed the delivered mRNA and all six mice infected with the virus survived the therapeutic period. After the initial screening of inhaled LNPs prescription, Anderson observed that LNPs formulations could be stabilized to resist inhalation-induced aggregation by altering the inhalation buffer to increase the LNPs charge during inhalation and by the addition of a branched polymeric excipient (
Fig. 4C and D)
39. This will greatly improve the inhalation effect of mRNA-LNPs. In addition, a dense PEG layer helps LNPs achieve pulmonary delivery of mRNA following inhalation
126,127. The density of PEG has an impact on the random motion of nanoparticles, which subsequently alters their movement within mucus
128,129. Studies have demonstrated that an increase in PEG content leads to higher efficiency in encapsulating mRNA and a reduction in the size of LNPs. However, an excess amount of the PEG layer inhibited receptor-mediated endocytosis by decreasing the adsorption of serum proteins and hindering the escape of LNPs from endosomes, thereby significantly limiting the intracellular delivery of mRNA
130—132. Therefore, Kim et al.
38 exploited
β-sitosterol, a phytosterol facilitating LNP’ endosomal escape, to meet such criteria. They adopted that combinations of
β-sitosterol and high PEG contents would permit nebulization, mucus penetration, and endosomal escape of LNPs. This inhaled LNPs retained its physicochemical properties and efficiently delivered mRNA after inhalation (
Fig. 4E). Interestingly, in a recent study, Liu et al.
40 developed a charge-assisted stabilization (CAS) strategy aimed at inducing electrostatic repulsions among LNPs to enhance their colloidal stability. By optimizing the surface charges using a peptide–lipid conjugate, the leading CAS-LNPs demonstrated exceptional stability during inhalation (
Fig. 4F). These factors affect the effectiveness and controllability of the inhaled mRNA-LNP delivery system.