An aerosol-assisted approach was devised to synthesize gefitinib anticancer drug-loaded chitosan nanocarriers (GefNCs). The nanocarrier synthesis involves mixing and interacting gefitinib molecules with chitosan natural polymer within a microfluidic chip. The combination was nebulized with an on-chip integrated micropneumatic nebulizer with N2 as the nebulizer gas. The aerosol was collected in a beaker containing a glutaraldehyde cross- linking agent while magnetically stirring. The chip was created by CO2 laser engraving on polymethyl meth- acrylate sheets. The synthesized GefNCs were characterized using FTIR, DLS, FESEM, and TEM. The FESEM images revealed a nanoparticle size distribution of 18.5 ± 4.6 nm. After adjusting numerous experimental pa- rameters such as chip design, polymer concentration, solution flow rate, and nebulizer gas flow rate, the syn- thesized nanocarrier’s release mechanism was investigated using various kinetic models. The results demonstrated that the release behavior of GefNCs is pH-sensitive and greater at acidic pH values than physio- logical pH, making the synthesized nanocarrier a potential for targeted gefitinib delivery to cancer cells. Furthermore, the kinetic studies revealed that the drug’s release mechanism best matches Fick’s diffusion rule. Under optimal conditions, the encapsulation efficiency was 77.8 %. The cytotoxicity of the produced nanocarrier was investigated on the A549 non-small cell lung carcinoma. The MTT test revealed that the produced nano- carrier had a lower IC50 than the free medication. Furthermore, cytotoxicity experiments on empty nanocarriers revealed that the materials utilized to synthesize nanocarriers have no appreciable cytotoxicity. The developed microfluidic-assisted approach provides a quicker synthesis procedure with a high encapsulation efficiency.
