The present study demonstrates that eicosapentaenoic acid (EPA), a natural omega-3 fatty acid, can serve as an effective liquid-lipid phase in methotrexate (MTX)-loaded nanostructured lipid carriers, yielding nanoscale carriers that combine a small particle size with high entrapment and a sustained release profile. Among the eight formulations examined, the optimal system (F5) simultaneously achieved the smallest particle size (88.92 nm), the highest entrapment efficiency (88.40%), and the highest drug loading (7.89%), indicating a favourable balance among the solid lipid, liquid lipid, and surfactant. A distinguishing feature of this work is that the liquid lipid was not a pharmacologically inert oil, as is common in conventional NLCs, but a bioactive natural compound, thereby integrating a structural role with additional formulation potential within a single carrier.
The favourable physicochemical profile of the optimal formulation can be rationalized on biophysical grounds. The incorporation of a liquid lipid such as EPA into a solid stearic-acid matrix is expected to disrupt the regular crystalline lattice, yielding a less ordered, more amorphous structure with a greater number of imperfections. These imperfections create additional space to accommodate drug molecules and reduce the tendency of the drug to be expelled as the lipid recrystallizes during storage; together, these effects account for the high entrapment and loading recorded for F5. This interpretation is consistent with the original conception of NLCs as second-generation lipid nanoparticles (
13-
16).
The encapsulation efficiency of F5 (88.40%) and its sub-100-nm particle size compare favourably with previously reported MTX-loaded lipid nanoparticles for topical use, in which entrapment values of ~70 - 90% and particle sizes of ~100 - 250 nm are typical (
22-
23). Comparable physicochemical characterization strategies have recently been applied to other nanocarrier systems, such as antibiotic-loaded alginate–chitosan nanogels, underscoring the general applicability of the present characterization approach (
40). Collectively, these comparisons indicate that EPA did not appear to compromise efficient drug encapsulation.
The particle size of all formulations remained below approximately 161 nm, and that of the optimal formulation was well under 100 nm; particle dimensions in this range are generally considered favourable for cutaneous delivery because they promote close contact with the stratum corneum and may facilitate accumulation within skin appendages and intercellular lipid domains (
11,
18-
21). The polydispersity index of the optimal formulation was 0.284, indicating a reasonably homogeneous population, and the negative zeta potential observed across the series (‒15.23 to ‒21.71 mV) is consistent with electrostatically stabilized dispersions. The preservation of both particle size and zeta potential over three months of refrigerated storage indicates adequate physical stability and the absence of significant aggregation, consistent with the established role of these parameters as critical quality attributes of lipid nanocarriers (
34-
35,
41).
The relationships between the formulation variables and the measured responses were not strictly monotonic; for example, the largest amounts of solid lipid did not yield the smallest particles or the highest loading, and intermediate compositions frequently outperformed the extremes. This behaviour indicates that carrier properties are governed by the interplay among the solid lipid, the liquid lipid, and the surfactant rather than by any single factor in isolation, underscoring the value of a systematic, multifactor approach to identifying a balanced composition (
42). It should be noted, however, that a formal analysis-of-variance decomposition of the main and interaction effects was not undertaken in this phase and is a defined objective of the ongoing optimization study.
The release of MTX from the optimal formulation followed a characteristic biphasic pattern, comprising an initial, relatively rapid phase followed by a slower, sustained phase. The initial phase is attributable to the fraction of drug located at or near the particle surface and within the surfactant layer, whereas the sustained phase reflects the gradual diffusion of drug entrapped within the lipid matrix. Comparison across four kinetic models showed that the first-order and Korsmeyer-Peppas models fitted the data comparably well, and the Korsmeyer-Peppas exponent (n = 1.12) indicated an anomalous (Super Case-II) transport regime rather than purely Fickian diffusion. This finding suggests that lipid-matrix relaxation and gradual erosion contribute to release alongside diffusion, as expected for the imperfect, matrix-type architecture of NLCs. Comparable sustained release has been reported for other MTX-loaded lipid nanoparticles intended for topical use (
22-
23), and such a profile is desirable for a topical carrier because it can prolong local drug availability while limiting peak concentrations associated with irritation.
Beyond its structural contribution, the selection of EPA as the liquid lipid is conceptually attractive. Unlike the inert oils customarily employed in NLCs, EPA is a bioactive natural compound with well-documented anti-inflammatory and antioxidant activities (
30-
32). The use of such a lipid as the structural liquid phase therefore raises the possibility of additional value from the carrier matrix itself; however, because no cellular or in vivo experiments were performed in this phase, any therapeutic contribution of EPA remains a hypothesis to be tested. Accordingly, EPA is characterized here strictly as a bioactive liquid lipid with high formulation potential rather than as a demonstrated therapeutic agent. The present study was deliberately confined to the design and physicochemical characterization of these carriers, which constitute the necessary foundation on which subsequent biological evaluation must rest.
Several limitations should be acknowledged. First, the present phase compared eight EPA-based compositions and did not include a conventional (inert-oil) liquid-lipid NLC as a comparator; such a control is planned to isolate the specific contribution of EPA. Second, solid-state and ultrastructural characterization—differential scanning calorimetry (DSC), X-ray diffraction (XRD), Fourier-transform infrared spectroscopy (FTIR), and transmission electron microscopy (TEM)—were beyond the present scope and are identified as important future prospects to confirm the crystallinity, drug–lipid interactions, and internal morphology inferred here. Third, only physical (colloidal) stability was assessed; because EPA is a polyunsaturated fatty acid susceptible to lipid peroxidation and MTX is prone to hydrolysis and photodegradation, chemical and oxidative stability were not quantified, and antioxidant protection together with forced-degradation studies are recommended. Finally, this work is limited to physicochemical and in vitro characterization: skin permeation, skin retention, cytocompatibility, and anti-inflammatory efficacy were not evaluated; therefore, the results should be interpreted as demonstrating formulation potential rather than therapeutic performance. Biological and skin-delivery validation remains necessary before therapeutic conclusions can be drawn.
In conclusion, EPA can function as a bioactive natural liquid lipid in MTX-loaded NLCs, yielding nanoscale, physically stable carriers with high entrapment, adequate drug loading, and sustained, predominantly diffusion-coupled release. By demonstrating that a bioactive omega-3 fatty acid can replace the inert liquid lipid of a conventional NLC without compromising physicochemical quality, these findings provide a rational basis for the design of topical lipid nanocarriers; however, the therapeutic value of this platform, and any specific contribution of EPA beyond its formulation role, must be confirmed in subsequent cellular and in vivo studies.