BACKGROUND: A novel ultrasonic atomization approach for the formulation of biodegradable poly(lactic-co-glycolic acid) (PLGA) microparticles of a malaria DNA vaccine is presented. A 40 kHz ultrasonic atomization device was used to create the microparticles from a feedstock containing 5 volumes of 0.5% w/v PLGA in acetone and 1 volume of condensed DNA which was fed at a flow rate of 18 ml h(-1). The plasmid DNA vectors encoding a malaria protein were condensed with a cationic polymer before atomization. RESULTS: High levels of gene expression in vitro were observed in COS-7 cells transfected with condensed DNA at a nitrogen to phosphate (N/P) ratio of 10. At this N/P ratio, the condensed DNA exhibited a monodispersed nanoparticle size (Z-average diameter of 60.8 nm) and a highly positive zeta potential of 38.8 mV. The microparticle formulations of malaria DNA vaccine were quality assessed and it was shown that the microparticles displayed high encapsulation efficiencies between 82-96% and a narrow size distribution in the range of 0.8-1.9 mu m. In vitro release profile revealed that approximately 82% of the DNA was released within 30 days via a predominantly diffusion controlled mass transfer system. CONCLUSIONS: This ultrasonic atomization technique showed excellent particle size reproducibility and displayed potential as an industrially viable approach for the formulation of controlled release particles. (C) 2009 Society of Chemical Industry