Combined Purification and Concentration by Deterministic Lateral Displacement with Product Recycle

Abstract

To provide a method of separating target cells or target particles of a predetermined size from a sample containing cells or particles of the predetermined size.SOLUTION: By recirculating product streams back onto microfluidic devices and applying them in the place of wash fluid, the final concentration of products is controlled. Initially, both sample and wash fluid are fed onto a device, and deterministic lateral displacement is performed on microfluidic devices while recirculating products, thereby simultaneously purifying and concentrating cells or other particles.SELECTED DRAWING: Figure 3

Description

[Technical Field]

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS This application claims the benefit of U.S. Provisional Patent Application No. 62 / 670,839, filed March 13, 2018.

[0002] FIELD OF THE INVENTION The present invention relates to a method for simultaneously purifying and concentrating cells or other particles by performing deterministic lateral displacement on a microfluidic device while recycling the product. [Background technology]

[0003] Deterministic lateral displacement (DLD) typically uses two co-flowing liquids: one containing the particles (sample) and the other a wash / collection fluid (the "run" or "wash" fluid). During DLD, particles above a critical diameter for the array are deflected into the wash fluid, while particles below the critical diameter follow the flow direction of the sample stream. The concentration of particles in the final product (collected) stream depends on the input concentration of particles in the sample stream, the ratio of sample to wash fluid, and the percentage of the total amount collected as product. Summary of the Invention [Problem to be solved by the invention]

[0004] It is possible to obtain high concentration factors using modern DLD procedures, but this may increase the risk of contamination (particles smaller than the critical diameter being collected in the product stream) or may require very long DLD arrays with extra redundancy to efficiently hit the narrow collection width. It is also difficult to adjust the concentration of the product produced by DLD to achieve consistency from run to run or to standardize results obtained across multiple donor samples with different input cell numbers. While samples can always be diluted, concentration is much more difficult. Samples with different input concentrations cannot be standardized to a single output concentration without pre-diluting each sample differently.

[0005] Another problem with controlling product concentration using current procedures is that relatively large volumes of wash solutions are typically required. Limiting these volumes would result in higher product concentrations, but there must always be enough wash solution to process the entire sample volume. [Means for solving the problem]

[0006] General description The present invention is based on the concept that it is possible to control the final concentration of DLD products by recirculating product streams through a microfluidic device and applying them in place of wash solutions. First, both the sample and wash solutions (also referred to more specifically herein as wash buffers or reagents) are supplied to the device. Then, at a selected point during the run, the inlet carrying the wash solution is sealed, and product from the device's outlet is supplied through the wash solution inlet. This can be achieved using standard valves. The recycled product flow can be propelled, for example, using a pressurized vessel, a peristaltic pump, or a syringe pump.

[0007] While the collected product (P1) is recirculated through the device, two processes occur. First, the sample flowing adjacent to the recirculated product is fractionated based on size, with larger particles deflected into the "wash stream" (here P1) and directed toward the product outlet. Second, because the particle count in P1 is increasing, the product concentration increases. A typical set of ratios is 60% sample and 40% wash at the inlet, and 20% product and 80% waste at the outlet. In this situation, if P1 is recirculated as wash, the particles in the wash stream are concentrated two-fold (40% / 20%) because they are still deflected into the array and product collection stream. Thus, the collected product (P2) contains both P1 cells, now two-fold concentrated, in addition to cells from the sample processed during that period.

[0008] One advantage of this method is that the final concentration of the output product depends on the number of recirculations and the initial wash volume used. Therefore, it can be easily adjusted. For example, for a very dilute donor sample, the operator can choose to run only a small sample volume through the wash and recirculate the product several times to process the remaining sample. As a result, a higher concentration factor can be obtained. This allows the operator (or instrumentation) to provide any output concentration, regardless of the input concentration. It also means that the instrument can be optimized to provide a fixed product concentration required for downstream assay steps, regardless of the input donor concentration. The user simply inputs the initial donor concentration and selects the desired output concentration. Using this information, the instrument adjusts the number of recirculations to achieve the selected value.

[0009] Another advantage of this method is that enrichment is achieved without the need for a separate enrichment device (performed in-line or as a second pass). Enrichment occurs in the same DLD used for cell isolation, and the time required to process the donor sample remains the same as if the sample were run only on wash buffer.

[0010] The volume of wash solution required is also significantly reduced. Instead of needing enough wash solution to process the entire sample, the wash volume is reduced by an amount corresponding to the volume of recirculated product. For example, if recirculation begins after about 50% of the sample has been processed, the amount of wash solution is reduced by about half.

[0011] Embodiment In its first aspect, the present invention relates to a method for separating target cells or particles of a predetermined size from a sample containing cells or particles less than the predetermined size. The method comprises applying a sample and a wash solution to a microfluidic device at separate inlets. The wash solution may be water or an aqueous buffer, and may optionally contain a reagent that chemically reacts with sample components, or an antibody, carrier, or activator that specifically interacts with the target cells or particles. As initially applied to the device, i.e., before product recycling, the wash solution should be devoid of target cells or particles and free of cells or particles less than the predetermined size.

[0012] The microfluidic device is preferably configured for deterministic lateral displacement (DLD), a process that involves flowing a sample through an array of specially designed microposts that are inclined at a small angle from the direction of fluid flow (Davis et al., Proc. Natl. Acad. Sci. USA 103:14779-14784 (2006); Inglis et al., Lab Chip 6:655-658 (2006); Chen et al., Biomicrofluidics. 9(5):054105 (2015)). Thus, the microfluidic device has an array of obstacles arranged in rows, with each subsequent row of obstacles being laterally shifted relative to the previous row. The obstacles should be positioned to deflect target cells or particles toward a first outlet (where they can be collected as product) and direct cells or particles below a predetermined size toward a second outlet (where they can be collected or discarded as waste).

[0013] DLD is performed by flowing a sample and a wash solution through the microfluidic device. During this process, at least a portion of the target cell or target particle product is recirculated through the first outlet, replacing all or at least a portion of the wash solution applied to the device inlet. During or at the end of the procedure, a final product containing the target cells or target particles is obtained from the first outlet.

[0014] To facilitate recirculation, a first outlet of the microfluidic device can include or be connected to a valve that can be used to divert the target cell or target particle product to a conduit that recirculates the target cell or target particle product to the inlet of the microfluidic device. Similarly, the microfluidic device can have an inlet that includes or is connected to a valve that can be used to switch the feed entering the device through the inlet from a conduit that provides wash fluid to a conduit that provides the target cell or target particle product.

[0015] In some embodiments, the target cells or particles recycled to the microfluidic plate react or bind with a carrier, antibody, fluorescent tag, activator, or compound before, during, or after being reapplied to the microfluidic device. In a preferred embodiment, target cells, such as white blood cells, or more specifically, T cells, are specifically bound by a carrier, antibody, or activator. When used in this context, the term "specificity" means that for each non-target cell bound to the sample, at least 100 (preferably at least 1,000) target cells are bound by the carrier. Such binding can be used to promote cell division (in the case of an activator) or to facilitate cell assay or further purification (in the case of an antibody).

[0016] Carriers can be used to modify cell behavior during the DLD procedure. For example, cells exiting a device at one location can be bound to a carrier to form a complex that exits the same device at a different location. Thus, size-based separations that would not otherwise be possible can be achieved. In this case, the carrier binding must be "so as to facilitate DLD separation." As used in this context, this term means that the method must ultimately result in binding that exhibits specificity for a particular target cell type, providing an increase in the size of the complex compared to unbound cells of at least 2 μm (or, expressed as a percentage, at least 20, 50, 100, 200, 500, or 1000%). If therapeutic or other applications require free target cells, this can allow them to be released from the complex by chemical or enzymatic cleavage, chemical lysis, digestion, competition with other binding agents, for example, by physical shear using a pipette to generate shear stress, or by other means. Carriers can also be bound to complement DLD separation.

[0017] To determine the concentration, a cell or particle count can be generated from the target cell or particle product. Based on this, a decision can be made as to whether to continue recycling the product. Depending on the objectives of the party performing the process, the cells or particles can be concentrated at least three-fold or at least ten-fold compared to their concentration in the sample. In the case of cells, recycling in combination with microfluidic processing is preferably the only method used for concentration during this process. This is particularly true for cells that are genetically engineered and / or used therapeutically.

[0018] The methods described herein can be used to separate and enrich cells from bioreactors, flasks, culture plates, culture bags, biological fluids or extracts, and tissue-derived preparations. Particularly preferred are white blood cells (preferably T cells, most preferably CAR-T cells) or stem cells of a predetermined size. Samples containing these cells can be blood, apheresis, leukapheresis, or leukapheresis-derived compositions, or leukoplak preparations, and typically contain platelets or red blood cells smaller than a predetermined size. Cells can also be genetically engineered by any method used in the art, including electrical, chemical, or nanoparticle-mediated transfection or viral transduction.

[0019] In some cases, recycled leukocytes or stem cells may be conjugated to carriers, antibodies, or activators in a manner that enhances or complements DLD separation. Binding should occur before, during, or after the cells have passed through the microfluidic device at least once and are recirculated into the microfluidic device. If the cells are to be used therapeutically, the cell preparation process should not include a centrifugation step, and recirculation should occur until or after a sufficient concentration of cells is obtained for therapeutic administration to the patient. Similarly, the addition of virus or genetic material to the concentration loop before release may be possible. Furthermore, when a sample is obtained from a patient for isolation of therapeutically used cells, it is preferable that no more than four hours elapse between the completion of sample acquisition and the completion of DLD cell processing.

[0020] It will be readily apparent to those skilled in the art that, with some modifications, the procedures described herein can be adapted to separate target cells or particles from larger sized contaminants. Apart from being directed to the above methods, the present invention includes cells (including leukocytes, stem cells and CAR-T cells) or particles produced by the methods.

[0021] Integrated method for producing purified genetically engineered target cells In a preferred embodiment, the above procedure may be used as part of a method for producing genetically engineered target cells. In particular, the present invention includes a method for producing purified genetically engineered target cells by: a) obtaining a sample containing target cells of a predetermined size and one or more contaminating cells or particles smaller than the predetermined size; b) applying the sample to a microfluidic device at a first inlet and a wash fluid at a second inlet, wherein the microfluidic device includes an array of obstacles arranged to differentially deflect the stream of target cells to a first outlet, where they are collected as a target cell product, and directing contaminating cells or particles smaller than the predetermined size to a second outlet, where they can be collected or discarded as waste; c) flowing the sample and wash fluid through the device, wherein the concentration of target cells at the first outlet is determined, and at least a portion of the target cells are recirculated from the outlet to replace, in whole or in part, the wash fluid applied to the inlet of the device. The circulation continues or is repeated until the desired product cell concentration, PC, is reached; d) upon reaching PC, direct the flow of target cells to be collected from the first outlet or to a site where they will be transformed or transfected to form genetically engineered target cells; e) if the target cells are transformed or transfected in step d), form genetically engineered target cells by flowing the genetically engineered target cells to a site or device where this purification occurs, preferably to purify the genetically engineered target cells from viruses, reagents, or other materials used during the genetic engineering to form purified genetically engineered target cells; f) collect the purified genetically engineered target cells produced in step e) or flow them to a site where they will be further processed before collection. In a preferred embodiment, all steps from applying the cells to the microfluidic device in step b) to collecting the cells are performed as a single continuous process. It is also preferred that no other means for concentrating target cells are used during this process other than the microfluidic separation via the product recycling procedure described above.

[0022] As used herein, the term "cells of a predetermined size" refers to the size of target cells selected for separation. The size can be either experimentally determined or known in the art. For example, the size of human T cells is known in the art, as are the sizes of platelets and red blood cells. Thus, a separation could be performed in which T cells are the "target cells of a predetermined size" and platelets and red blood cells are the contaminant cells to be separated. The term "predetermined size" can also be used in the context of designing a microfluidic device for separation. For example, the term "critical size" or "predetermined size" of particles passing through an obstacle array can be used to describe the size limit of particles that can be tracked through a laminar fluid flow. Larger particles may, for example, be "bumped" out of the fluid flow channel, but particles smaller than the critical size (or predetermined size) are not necessarily displaced.

[0023] Many types of cells can be used as target cells, including therapeutically active cells such as lymphocytes and stem cells. T lymphocytes are particularly preferred because they can be genetically engineered to produce chimeric antigen receptors (CARs) on their surface, forming therapeutically valuable chimeric antigen receptor T cells.

[0024] The most preferred process for separating target cells from cells or particles smaller than a predetermined size, i.e., steps b) and c), is by DLD. DLD can also be used in step e) to separate the genetically engineered target cells from reagents, viruses, or other materials used to transform or transfect the target cells. If the genetically engineered cells are grown in cell culture (typically in the production of CAR T cells), the materials used to transform or transfect the target cells can be removed in step e) while simultaneously transferring the cells to growth medium. The transferred cells can be collected and cultured, or can be directly transferred to the location where the culture will occur.

[0025] The wash solution used in the above methods may be water or an aqueous buffer, and may contain reagents that chemically react with cells, particles or other components in the wash solution, or may contain antibodies, carriers or activators that specifically interact with target cells.

[0026] Generally, the direction of target cells exiting the device is by an outlet that includes or is connected to a valve. Depending on whether the valve is open or closed, the valve directs the target cells: a) from the outlet to a conduit that recirculates the cells to an inlet on the microfluidic device, or b) from the outlet to a site where the target cells are transformed or transfected to form genetically engineered target cells. Preferably, the valve electronically responds to concentrations of target cells below a desired concentration, PC, by directing the target cells to a conduit that recirculates the cells to an inlet on the microfluidic device, and electronically responds to concentrations of target cells equal to or greater than PC by directing the target cells to a site where they are collected or where they are transformed or transfected to form genetically engineered target cells.

[0027] Target cells recycled to the microfluidic device inlet may react or bind with carriers, antibodies, fluorescent tags, activators, or compounds before, during, or after reapplication to the microfluidic device. For example, white blood cells or stem cells may bind to carriers, antibodies, or activators in a manner that enhances or complements DLD separation.

[0028] Recycling of target cells can be continued until the target cells are concentrated at least 3-fold, preferably at least 5-fold, and even more preferably at least 10-fold relative to their concentration in the sample. It is also preferred that the target cells are not centrifuged or frozen between the time the sample is collected in step a) and the time the cells are collected. Furthermore, the sample is preferably obtained from a patient who will ultimately be treated with the generated cells, and step f) is completed within 10 hours (preferably within 5 hours) from the time the sample is collected.

[0029] The most preferred sample is blood or a composition obtained by processing blood, for example, by apheresis or leukapheresis. This type of sample can be used, for example, to separate white blood cells from platelets and / or red blood cells.

[0030] The present invention encompasses not only the above-described methods, but also purified genetically engineered target cells produced by the methods, therapeutic compositions based on these cells, and methods in which the therapeutic compositions are used to treat patients. [Brief explanation of the drawings]

[0031] [Figures 1A-1C] Figures 1A-1C illustrate various modes of operation for one type of DLD device. These include i) separation (Figure 1A), ii) buffer exchange (Figure 1B), and iii) concentration (Figure 1C). In each mode, essentially all particles above a critical diameter are deflected from the entry point toward the array, resulting in size selection, buffer exchange, or concentration as a function of the device geometry. In all cases, particles below the critical diameter pass directly through the device under laminar flow conditions and then exit the device at the exit. DLD devices have been described in the literature, along with methods for making and using the devices (see, e.g., U.S. Patent Application Publication No. 2016 / 0139012; U.S. Patent Application Publication No. 2017 / 0333900; U.S. Patent Application Publication No. 2016 / 0047735; U.S. Patent Application Publication No. 2017 / 0209864; U.S. Patent Application Publication No. 2017 / 0248508; and U.S. Patent Application Publication No. 2019 / 0071639, the entire contents of which are incorporated herein by reference). [Figure 1D] Figure ID shows a 14-lane DLD design used in separation mode. The illustrated array and microchannels have a total length of 75 mm and a width of 40 mm, with individual lanes measuring 1.8 mm wide. [Figure 1E] Figure IE shows a close-up of the plastic diamond post array and the integrated collection port at the outlet. [Figure 1F]Figure IE shows a close-up of the plastic diamond post array and the integrated collection port at the outlet. [Figure 1G] FIG. 1G shows a photograph of a leukapheresis product being processed using the device. [Figure 2] FIG. 2 is a schematic diagram showing how individual chips are now designed to be stackable in layers to achieve the throughput required for a particular application. [Figure 3] The leftmost diagram in Figure 3 illustrates the movement of cells during DLD. Buffer and sample are applied to the device through separate inlets. As the sample moves toward the outlet, cells larger than the critical size of the array move from the sample stream (the hatched area outside the channel) to the buffer stream (the stippled area in the center of the channel) and finally exit the product outlet. Panels 1–3 illustrate various steps in the DLD procedure, including product recycling. In panel 1, sample (white in the upper sample reservoir) and buffer (stippled area in the upper buffer reservoir) are applied to the microfluidic device through separate inlets. The product, including cells larger than the critical size of the array, is collected through the product outlet (stippled area in the lower product reservoir), and waste is collected through the waste outlet (clear area in the lower waste reservoir). Note that the valve from the product reservoir to the buffer inlet is closed, while the valve from the buffer reservoir to the buffer inlet is open. In panel 2, the valve from the product reservoir to the buffer inlet is open, and the valve from the buffer reservoir to the buffer inlet is closed. As a result, the product is recycled back into the microfluidic device. In panel 3, the process is nearly complete. The total amount of waste increases and the total amount of product decreases. DETAILED DESCRIPTION OF THE INVENTION

[0032] Illustrative Table The expected calculation results from the procedure are shown in the table below. The numbers are based on a selected set of input and output conditions for a 14-lane microfluidic device. It should be recognized that microfluidic devices with different layouts (and inlet / outlet ratios) will have numbers on a different scale.

[0033] [Table 1]

[0034] [Table 2]

[0035] [Table 3]

[0036] [Table 4]

[0037] [Table 5]

[0038] definition Apheresis: As used herein, this term refers to a procedure in which blood from a patient or donor is separated into its components, such as plasma, white blood cells, and red blood cells. More specific terms are "plateletpheresis" (referring to the separation of platelets) and "leukopheresis" (referring to the separation of white blood cells). In this context, the term "separation" refers to obtaining a product enriched in a particular component compared to whole blood, and does not imply that absolute purity has been achieved.

[0039] CAR T cells: The term "CAR" is an acronym for "chimeric antigen receptor." Thus, a "CAR T cell" is a T cell genetically engineered to express a chimeric receptor. Methods for making and using CAR T cells are well known in the art. Procedures are described, for example, in U.S. Pat. No. 9,629,877; U.S. Pat. No. 9,328,156; U.S. Pat. No. 8,906,682; U.S. Patent Application Publication No. 2017 / 0224789; U.S. Patent Application Publication No. 2017 / 0166866; U.S. Patent Application Publication No. 2017 / 0137515; U.S. Patent Application Publication No. 2016 / 0361360; U.S. Patent Application Publication No. 2016 / 0081314; U.S. Patent Application Publication No. 2015 / 0299317; and U.S. Patent Application Publication No. 2015 / 0024482, which are incorporated herein by reference.

[0040] CAR T-cell therapy: This term refers to any procedure in which a disease is treated with CAR T cells. Diseases that can be treated include blood and solid tumor cancers, autoimmune diseases, and infectious diseases.

[0041] Carrier: As used herein, the term "carrier" refers to an agent, e.g., a bead or particle, made of either biological or synthetic materials, that is added to a preparation for the purpose of binding directly or indirectly (i.e., via one or more intermediary cells, particles, or compounds). Carriers can be made of a variety of materials, such as DEAE-dextran, glass, polystyrene plastic, acrylamide, collagen, or alginate, and typically range in size from 1 to 1,000 μm. They can be coated or uncoated. Carriers with surfaces modified to contain affinity agents (e.g., antibodies, activators, haptens, aptamers, particles, or other compounds) that recognize antigens or other molecules on the surface of cells can also be magnetized, which can provide an additional purification means to complement DLD. They can also contain particles (e.g., Janus or strawberry-like particles) that confer secondary properties to cells or cell complexes that are not size-related.

[0042] For example, particles may provide chemical, electrochemical, or magnetic properties that can be used in downstream processes such as magnetic separation, electroporation, gene transfer, and / or certain analytical chemistry processes. Particles may also induce metabolic changes in cells, activate cells, or promote cell division.

[0043] Carriers bound "in a manner that promotes DLD separation": This term, depending on the context, refers to carriers and methods of binding carriers that affect how cells, proteins, or particles behave during DLD. Specifically, "bound in a manner that promotes DLD separation" means: a) the binding must be specific for a particular target cell type, protein, or particle; and b) it must produce a complex that increases the size of the complex compared to the unbound cell, protein, or particle. When bound to a target cell, an increase of at least 2 μm is required (or, expressed as a percentage, at least 20, 50, 100, 200, 500, or 1000%). If a therapeutic or other application requires that target cells, proteins, or other particles be released from the complex to fulfill their intended use, the term "in a manner that promotes DLD separation" also requires that the complex permit such release. Chemical or enzymatic cleavage, chemical lysis, digestion, and the released target cells, proteins, or other particles must remain active, whether by competition with other binding agents or by physical shear (e.g., using a pipette to generate shear stress). For example, the therapeutic cells after release from the conjugate must still maintain the biological activity that makes them therapeutically useful.

[0044] Carriers may be bound "in a manner complementary to DLD separation": This term refers to carriers and methods of binding carriers that alter the chemical, electrochemical, or magnetic properties of cells or cell complexes, or alter one or more biological activities of the cells, regardless of whether they increase the size sufficiently to facilitate DLD separation. Carriers that complement DLD separation also do not necessarily bind specifically to target cells; i.e., they may need to be combined with other agents that make them specific, or they may simply be added to a cell preparation to allow nonspecific binding. The terms "in a manner complementary to DLD separation" and "in a manner that promotes DLD separation" are not mutually exclusive. Binding may complement and promote DLD separation. For example, a polysaccharide carrier may have an activator on its surface that increases the rate of cell proliferation; binding of one or more of these carriers may also promote DLD separation. Alternatively, binding may only promote or complement DLD separation.

[0045] Target Cell: As used herein, a "target cell" is a cell that the various procedures described herein require or are designed to purify, collect, manipulate, etc. What a particular cell is depends on the context in which the term is used. For example, if the purpose of a procedure is to isolate a particular type of stem cell, that cell would be the target cell for the procedure.

[0046] Isolation, Purification: Unless otherwise specified, these terms, as used herein, are synonymous and refer to the enrichment of a desired product relative to undesired materials. These terms do not necessarily mean that the product is completely separated or completely pure. For example, if a starting sample has target cells that make up 2% of the cells in the sample, and a procedure is performed that results in a composition in which the target cells are 60% of the cells present, the procedure would be successful in isolating or purifying the target cells.

[0047] Deterministic Lateral Displacement: As used herein, the term "deterministic lateral displacement" or "DLD" refers to a process in which particles are deterministically deflected on a path through an array based on their size, which is related to several array parameters. The process is generally described herein in terms of continuous flow (DC conditions; i.e., bulk fluid flow in one direction only). However, DLD also works with oscillatory flow (AC conditions; i.e., bulk fluid flow that alternates between two directions).

[0048] Critical Size: The "critical size" or "predetermined size" of a particle passing through an obstacle array represents the size limit of a particle that can track through the laminar flow of a fluid. Particles larger than the critical size may be "dropped" from the fluid flow channel, while particles smaller than the critical size (or predetermined size) are not necessarily so displaced. If the fluid flow profile through the gap is symmetrical with respect to a plane that bisects the gap in the direction of bulk fluid flow, the critical size may be the same on both sides of the gap; however, if the profile is asymmetrical, the critical size on both sides of the gap may be different.

[0049] Fluid Flow: As used herein in connection with DLDs, the terms "fluid flow" and "bulk fluid flow" refer to the macroscopic movement of fluid in a general direction across an array of obstacles. These terms do not take into account temporary displacements of the fluid flow as the fluid moves around obstacles so that the fluid continues to move in all directions.

[0050] Tilt angle ε: In a bump array device, the tilt angle is the angle between the direction of bulk fluid flow and the direction defined by the alignment of successive rows of obstacles (in the direction of bulk fluid flow) in the array.

[0051] Array direction: In a bump array device, the "array direction" is the direction defined by the arrangement of successive rows of obstacles in the array. A particle is "bumped" (dropped) in the bump array if, when passing through a gap and encountering a downstream obstacle, the particle's overall trajectory follows the array direction of the bump array (i.e., it moves at an oblique angle ε relative to the bulk fluid flow). Under such circumstances, if the particle's overall trajectory follows the direction of the bulk fluid flow, the particle is not dropped.

[0052] Detailed Description of the Invention The present invention relates to the use of DLD in preparing cells of therapeutic value. The following text provides general guidance regarding the methods disclosed herein, as well as information that may assist in the manufacture and use of devices involved in carrying out those methods.

[0053] I. Microfluidic Plate Design Cells, particularly cells in compositions prepared by apheresis or leukapheresis, and particles can be separated by DLD using microfluidic devices containing channels through which fluid flows from one or more inlets at or near one end of the device to an outlet at or near or on the opposite end. The basic principles of size-based microfluidic separation and the design of obstacle arrays for separating cells are provided in other applications (see U.S. Patent Application Publication No. 2014 / 0342375; U.S. Patent Application Publication No. 2016 / 0139012; U.S. Patent No. 7,318,902; and U.S. Patent No. 7,150,812, which are incorporated herein by reference). These are also summarized in the following sections.

[0054] During DLD, a fluid sample containing particles or cells is introduced into the device at the inlet and carried with the fluid flowing through the device to the outlet. As cells in the sample pass through the device, they encounter struts or other obstacles arranged in rows, which form gaps or pores through which the cells must pass. Each successive row of obstacles is displaced relative to the previous row, forming an array direction that differs from the direction of fluid flow in the flow channel. The "tilt angle" defined by these two directions, along with the width of the gap between obstacles, the shape of the obstacles, and the orientation of the gap-forming obstacles, are the primary factors determining the "critical size" of the array. Cells larger than the critical size migrate toward the array rather than the direction of bulk fluid flow, while particles smaller than the critical size migrate toward the bulk fluid flow. For devices used for apheresis or leukapheresis-derived compositions, array characteristics can be selected that result in leukocytes being diverted toward the array while red blood cells and platelets continue in the direction of bulk fluid flow. To separate a selected type of leukocyte from other leukocytes of similar size, a carrier can then be used that binds to the cells in a manner that promotes DLD separation, thereby resulting in complexes that are larger than the uncomplexed leukocytes. It may then be possible to perform the separation on a device that has a critical size that is smaller than the complexes but larger than the uncomplexed cells.

[0055] The obstacles used in the device may be in the form of pillars, or may be in the form of triangles, squares, rectangles, diamonds, trapezoids, hexagons, or teardrops. Additionally, adjacent obstacles may have shapes such that the portions of the obstacles that define a gap are either symmetrical or asymmetrical with respect to the axis of the gap that extends in the direction of bulk fluid flow.

[0056] II. Microfluidic Device Fabrication and Operation General procedures for making and using microfluidic devices capable of separating cells or particles based on size are well known in the art. Such devices include those described in U.S. Patent Nos. 5,837,115; 7,150,812; 6,685,841; 7,318,902; 7,472,794; and 7,735,652, all of which are incorporated herein by reference. Other references that provide guidance that may be useful in making and using the devices of the present invention include: U.S. Patent No. 7,276,170; U.S. Patent No. 6,913,697; U.S. Patent No. 7,988,840; U.S. Patent No. 8,021,614; U.S. Patent No. 8,282,799; U.S. Patent No. 8,304,230; U.S. Patent No. 8,579,117; U.S. Patent Application Publication No. 2006 / 0134599; U.S. Patent Application Publication No. 2007 / 0160503; U.S. Patent Application Publication No. Publication No. 2005 / 0282293; U.S. Patent Application Publication No. 2006 / 0121624; U.S. Patent Application Publication No. 2005 / 0266433; U.S. Patent Application Publication No. 2007 / 0026381; U.S. Patent Application Publication No. 2007 / 0026414; U.S. Patent Application Publication No. 2007 / 0026417; U.S. Patent Application Publication No. 2007 / 0026415; U.S. Patent Application Publication No. 2 007 / 0026413; U.S. Patent Application Publication No. 2007 / 0099207; U.S. Patent Application Publication No. 2007 / 0196820; U.S. Patent Application Publication No. 2007 / 0059680; U.S. Patent Application Publication No. 2007 / 0059718; U.S. Patent Application Publication No. 2007 / 005916; U.S. Patent Application Publication No. 2007 / 0059774; U.S. Patent Application Publication No. 2007 / 0 059781; U.S. Patent Application Publication No. 2007 / 0059719; U.S. Patent Application Publication No. 2006 / 0223178; U.S. Patent Application Publication No. 2008 / 0124721; U.S. Patent Application Publication No. 2008 / 0090239; U.S. Patent Application Publication No. 2008 / 0113358; and WO2012 / 094642, which are hereby expressly incorporated by reference.Among the various references describing device fabrication and use, U.S. Patent No. 7,150,812 provides particularly good guidance, and U.S. Patent No. 7,735,652 is of particular interest with respect to microfluidic devices for separations performed on samples containing cells found in blood (see U.S. Patent Application Publication No. 2007 / 0160503 in this regard).

[0057] Devices can be fabricated using any of the materials from which microscale and nanoscale fluid handling devices are typically fabricated, including silicon, glass, plastics, hybrid materials, etc. A variety of thermoplastic materials suitable for microfluidic fabrication are available, offering a wide selection of mechanical and chemical properties that can be exploited and further tailored to specific applications.

[0058] Techniques for fabricating devices include replica molding, soft lithography using PDMS, thermosetting polyesters, embossing, injection molding, laser ablation, and combinations thereof. Further details can be found in "Disposable microfluidic devices: fabrication, function, and application" by Fiorini et al., BioTechniques 38:429-446 (March 2005), which is incorporated herein by reference. "Lab on a Chip Technology," edited by Keith E. Herold and Avraham Rasooly, Caister Academic Press, Norfolk, UK (2009), is another resource for fabrication methods and is incorporated herein by reference.

[0059] High-throughput embossing methods, such as reel-to-reel processing of thermoplastics, are attractive methods for industrial microfluidic chip fabrication. The use of single-chip hot embossing is a cost-effective approach for achieving high-quality microfluidic devices at the prototyping stage. Methods for replicating microscale features in two thermoplastics, polymethyl methacrylate (PMMA) and / or polycarbonate (PC), are described by Yangra in "Microfluidic Device Fabrication by Thermoplastic Hot Embossing," Methods Mol. Biol., 949:115-23 (2013), which is incorporated herein by reference.

[0060] A flow channel can be constructed using two or more parts that, when assembled, form a closed cavity (preferably one with an orifice for adding or withdrawing fluid) within which an obstacle is located. The obstacle can be fabricated on one or more of the parts assembled to form the flow channel, or can be fabricated in the form of an insert sandwiched between two or more parts that define the boundaries of the flow channel.

[0061] An obstacle can be a solid object that traverses the flow channel, possibly extending from one side of the flow channel to the opposite side of the flow channel. If the obstacle is integral with (or an extension of) one of the sides of the flow channel at one end of the obstacle, the other end of the obstacle can be sealed or pressed against the opposite side of the flow channel. A small space (preferably too small to accommodate particles of interest for the intended application) between one end of the obstacle and the side of the flow channel is acceptable, as long as it does not adversely affect the structural stability of the obstacle or the proper flow characteristics of the device.

[0062] The number of obstacles present must be sufficient to achieve the particle separation properties of the array. The obstacles may typically be organized into rows and columns (Note: the use of the term "rows and columns" does not imply or imply that the rows and columns are perpendicular to one another). Obstacles that are generally aligned transverse to the flow of fluid in a flow channel may be referred to as obstacles in a column. Obstacles adjacent to one another in a column may define gaps through which fluid can flow.

[0063] Obstacles in adjacent columns may be offset from one another by a degree characterized by a tilt angle called ε (epsilon). Thus, for several adjacent columns (i.e., several columns of obstacles passed sequentially by a generally unidirectional fluid flow across the columns), corresponding obstacles within a column may be offset from one another. Rows of obstacles extend at an angle ε relative to the direction of fluid flow through the columns. The tilt angle can be selected to separate the columns from one another such that 1 / ε (expressed in radians) is an integer and the columns of obstacles are periodically repeated. Obstacles within a single column may also be offset from one another by the same or different tilt angles. As an example, rows and columns can be positioned at 90-degree angles relative to one another, with both rows and columns tilted at the same angle ε relative to the direction of bulk fluid flow through the flow channel.

[0064] Surfaces can be coated to modify their properties, and polymeric materials used to fabricate devices can be altered in various ways. In some cases, functional groups such as amines and carboxylic acids, either present in natural polymers or added by wet chemistry or plasma treatment, are used to crosslink proteins or other molecules. DNA can be attached to COC and PMMA substrates using surface amine groups. Surfactants such as Pluronic® can be used to make surfaces hydrophilic and protein-repellent by adding Pluronic® to PDMS formulations. In some cases, a layer of PMMA is spin-coated onto a device, such as a microfluidic chip, and the PMMA is "doped" with hydroxypropyl cellulose to alter its contact angle.

[0065] To reduce nonspecific adsorption of cells or compounds, for example, released by lysed cells or found in biological samples, to the channel walls, one or more walls can be chemically modified to make them nonadhesive or repelling. The walls can be coated with a thin film coating (e.g., a monolayer) of commercially available nonadhesive reagents, such as those used to form hydrogels. Additional examples of chemical species that can be used to modify the channel walls include oligoethylene glycols, fluorinated polymers, organosilanes, thiols, polyethylene glycols, hyaluronic acid, bovine serum albumin, polyvinyl alcohol, mucin, polyHEMA, methacrylated PEG, and agarose. Charged polymers, such as heparin, can be used to repel oppositely charged species. The type of chemical species used for repulsion and the method of attachment to the channel walls can depend on the nature of the species being repelled and the nature of the wall and the species being attached. Such surface modification techniques are well known in the art. The walls can be functionalized before or after the device is assembled.

[0066] III. Separation Process Using DLD The DLD devices described herein can be used to purify cells, cell fragments, cell adducts, or nucleic acids. As discussed herein, these devices can also be used to separate a cell population of interest from multiple other cells. Separation and purification of blood components using the devices can be found, for example, in U.S. Patent Application Publication No. US2016 / 0139012, the teachings of which are incorporated herein by reference. A brief description of some exemplary separations follows.

[0067] A. Viable cells In one embodiment, the device is used in a procedure designed to separate viable cells from nonviable cells. The term "viable cells" refers to cells that are capable of growth, actively dividing, replicating, etc. When viable cells have a larger size than nonviable cells, the DLD device can be designed to contain a critical size that is larger than the predetermined size of nonviable cells and smaller than the predetermined size of viable cells. The critical size may be only 1.1 times larger (or smaller) than the predetermined size of nonviable cells, but is generally larger (or smaller), e.g., about 1.2 to 2 times, preferably 3 to 10 times.

[0068] B. Adherent cells In another embodiment, the DLD device may be used to separate adherent cells. As used herein, the term "adherent cells" refers to cells that can adhere to a surface. Adherent cells include immortalized cells used in cell culture and may be derived from a mammalian host. In some instances, adherent cells may be trypsinized prior to purification. Examples of adherent cells include MRC-5 cells; HeLa cells; Vero cells; NIH3T3 cells; L929 cells; Sf21 cells; Sf9 cells; A549 cells; A9 cells; AtT-20 cells; BALB / 3T3 cells; BHK-21 cells; BHL-100 cells; BT cells; Caco-2 cells; Chang cells; Clone 9 cells; Clone 10 cells; These include M-3 cells; COS-1 cells; COS-3 cells; COS-7 cells; CRFK cells; CV-1 cells; D-17 cells; Daudi cells; GH1 cells; GH3 cells; HaK cells; HCT-15 cells; HL-60 cells; HT-1080 cells; HT-29 cells; HUVEC cells; I-10 cells; IM-9 cells; JEG-2 cells; Jensen cells; Jurkat cells; K-562 cells; KB cells; KG-1 cells; L2 cells; LLC-WRC256 cells; McCoy cells; MCF7 cells; WI-38 cells; WISH cells; XC cells; Y-1 cells; CHO cells; Raw264.7; BHK-21 cells; HEK293 cells, including 293A, 293T, etc.; HEP G2 cells; BAE-1 cells; SH-SY5Y cells; and derivatives, engineered strains, and recombinant strains thereof.

[0069] In some embodiments, the procedure can include separating the cells from a diluent, such as growth medium, which can provide efficient maintenance of the adherent cell culture. For example, a culture of adherent cells in growth medium can be exchanged for a transfection medium containing a transfection reagent, a second growth medium designed to induce changes in the adherent cells, such as stem cell differentiation, or a series of wash buffers designed to remove compounds from the culture medium.

[0070] In a preferred procedure, adherent cells are purified through association with one or more carriers that bind in a manner that facilitates DLD separation. The carriers can be of the types described herein, and the binding can stabilize and / or activate the cells. Carriers are typically in the 1-1000 μm range, although they can be outside this range.

[0071] The association between the carrier and the cells should produce a complex that is increased in size compared to other materials not associated with the carrier. Depending on the specific size of the cells and carrier and the number of cells and carriers present, the complex may be anywhere from a few percent larger than the uncomplexed cells to many times the size of the uncomplexed cells. To facilitate separation, an increase of at least 20% is desirable, with higher percentages (50; 100; 1000 or more) being preferred.

[0072] C. Activated cells The DLD device can also be used in procedures to separate activated or activatable cells from multiple other cells. While cells undergoing activation can be expanded on a large scale, in a preferred embodiment, the cells are derived from a single patient and DLD is performed within at least a few hours of collection. The terms "activated cells" and "activatable cells" refer to cells that have been activated or can be activated, respectively, through association, incubation, or contact with a cell activator. Examples of activatable cells include T cells, B cells; cells that play a role in immune or inflammatory responses, such as regulatory T cells, macrophages, dendritic cells, granulocytes, innate lymphoid cells, megakaryocytes, natural killer cells, platelets, and synoviocytes; cells that play a role in metabolism, such as beta cells, hepatocytes, and pancreatic cells; and recombinant cells capable of inducible protein expression, such as DE3-lysogenized E. coli cells, yeast cells, and plant cells.

[0073] Typically, an activator is present on the surface of one or more carriers. Examples of cellular activators include proteins, antibodies, cytokines, CD3, CD28, antigens against specific proteins, helper T cells, receptors, and glycoproteins; hormones such as insulin and glucagon; IPTG, lactose, allolactose, lipids, glycosides, terpenes, steroids, and alkaloids. The activatable cells should be at least partially associated with the carrier through interactions between the activatable cells and the cellular activator on the carrier surface. The complexes formed may be only a few percent larger than uncomplexed cells or many times larger than the size of uncomplexed cells. To facilitate separation, an increase of at least 20% is desirable, with higher percentages (40, 50, 100, 1000, or more) being preferred.

[0074] D. Separation of cells from toxic substances DLDs can also be used in purification processes designed to remove compounds that may be toxic to cells or to protect cells from contamination by toxic compounds. Examples include antibiotics, cryopreservatives, antifungals, toxic metabolites, sodium azide, metal ions, metal ion chelators, endotoxins, plasticizers, pesticides, and any combination thereof. This device can be used to remove toxic compounds from cells and ensure consistent production of materials from cells. In some instances, the cells may be log-phase cells. The term "log-phase cells" refers to cells that are actively dividing during a growth phase characterized by exponential logarithmic growth. During logarithmic phase, a cell population may double at a constant rate, such that plotting the natural logarithm of cell number against time produces a straight line.

[0075] The ability to isolate toxic substances has been demonstrated in bacterial strains such as BL21, Tuner, Origami, Origami B, Rosetta, C41, C43, DH5α, DH10β, or XL1Blue; yeast strains such as Saccharomyces, Pichia, Kluyveromyces, Hansenula, and Yarrowia; algae; MRC-5 cells; HeLa cells; Vero cells; NIH3T3 cells; L929 cells; Sf21 cells; Sf9 cells; A549 cells; A9 cells; AtT-20 cells; BALB / 3T3 cells; BHK-21 cells; BHL-100 cells; BT cells; Caco-2 cells; Chang cells; Clone 9 cells; M-3 cells;COS-1 cells;COS-3 cells;COS-7 cells;CRFK cells;CV-1 cells;D-17 cells;Daudi cells;GH1 cells;GH3 cells;HaK cells;HCT-15 cells;HL-6 0 cells; HT-1080 cells; HT-29 cells; HUVEC cells; I-10 cells; IM-9 cells; JEG-2 cells; Jensen cells; Jurkat cells; K-562 cells; KB cells; KG-1 cells; It is of interest for a wide variety of cells, including L2 cells; LLC-WRC256 cells; McCoy cells; MCF7 cells; WI-38 cells; WISH cells; XC cells; Y-1 cells; CHO cells; Raw264.7; BHK-21 cells; HEK293 cells (including 293A, 293T, etc.); HEPG2 cells; BAE-1 cells; SH-SY5Y cells; stem cells and their derivatives (including engineered and recombinant lines).

[0076] V. Technical background Without being bound by any particular theory, a general discussion of some technical aspects of microfluidics can be useful in understanding the factors that influence the separations performed in this field. Various microfabricated sieving matrices for particle separation have been disclosed (Choura, Proc. Natl. Acad. Sci., 96:13762 (1999); Hanra, Science, 288:1026 (2000); Huangra, Nat. Biotechnol. 20:1048 (2002); Turner et al., Phys. Rev. Lett. 88(12):128103 (2002); Huang et al., Phys. Rev. Lett. 89:178301 (2002); U.S. Patent No. 5,427,663; U.S. Patent No. 7,150,812; U.S. Patent No. 6,881,317). Bump array (also known as "obstacle array") devices have been described, and their basic operation is explained, for example, in U.S. Pat. No. 7,150,812, which is incorporated herein by reference in its entirety. Bump arrays essentially operate by separating particles passing through an array of obstacles (usually a periodically ordered array), with separation occurring between particles that follow an "array direction" that is offset from the direction of bulk fluid flow or the direction of an applied field (U.S. Pat. No. 7,150,812).

[0077] A. Bump Array In some arrays, the geometry of adjacent obstacles is such that the portion of the obstacle that defines the gap is symmetrical about the gap's axis, which extends in the direction of bulk fluid flow. The velocity or volume profile of fluid flow through such a gap is approximately parabolic across the gap, with fluid velocity and flux being zero at the surface of each gap-defining obstacle (assuming no-slip flow conditions) and reaching a maximum value at the center of the gap. Because the profile is parabolic, a fluid layer of a particular width adjacent to one of the gap-defining obstacles contains the same proportion of fluid flux as a fluid layer of the same width adjacent to the other gap-defining obstacle, meaning that the size of a particle that is "bumped" while passing through the gap will be equal regardless of which obstacle the particle moves near.

[0078] In some cases, the particle size separation performance of an obstacle array can be improved by shaping and arranging the obstacles so that the portion of the adjacent obstacle that deflects fluid flow into the gap between the obstacles is not symmetrical with respect to the axis of the gap, which extends in the direction of bulk fluid flow within the obstacle. This lack of flow symmetry into the gap can lead to an asymmetric fluid flow profile within the gap. Concentration of fluid flow toward one side of the gap (i.e., the result of an asymmetric fluid flow profile through the gap) can reduce the critical size of particles induced to move toward the array rather than in the direction of bulk fluid flow. This is because the asymmetry in the flow profile creates a difference between the width of the flow layer adjacent to one obstacle containing a selected percentage of fluid flux through the gap and the width of the flow layer containing the same percentage of fluid flux adjacent to the other obstacle that defines the gap. The different widths of the fluid layers adjacent to the obstacles define gaps that exhibit two different critical particle sizes. Particles passing through the gap may collide (i.e., move toward the array rather than in the direction of bulk fluid flow) if they exceed the critical size of the fluid layer through which they are carried. Thus, particles passing through a gap with an asymmetric flow profile may collide if the particles travel through the fluid layer adjacent to one obstacle, but may not collide if the particles travel through the fluid layer adjacent to the other obstacle that defines the gap.

[0079] In another aspect, the particle size separation performance of an obstacle array can be improved by reducing the roundness of the edges of the obstacles that define the gaps. For example, an array of obstacles with triangular cross-sections with sharp vertices can exhibit a lower critical particle size than an array of triangular obstacles of the same size and spacing with rounded vertices.

[0080] Thus, by sharpening the edges of the obstacles that define the gaps in the obstacle array, the critical size of particles that will be deflected toward the array under the influence of bulk fluid flow can be reduced without necessarily reducing the size of the obstacles. Conversely, obstacles with sharper edges will provide particle separation properties equivalent to obstacles of the same size that do not have sharper edges, but can still be spaced farther apart.

[0081] B. Fractionation Range Objects that can be separated by size on microfluidic devices include cells, biomolecules, inorganic beads, and other objects. Typical sizes separated range from 100 nanometers to 50 micrometers, although larger and smaller particles may also be fractionated.

[0082] C. Volume Depending on the design, a device or combination of devices can be used to process samples of about 10 μl to at least 500 μl, about 500 μl to about 40 mL, about 500 μl to about 20 mL, about 20 mL to about 200 mL, about 40 mL to about 200 mL, or at least 200 mL. The total volume of material processed can be 50 mL to 5000 mL, 100 mL to 4000 mL, or 500 mL to 2000 mL, in some cases. Starting materials include blood, blood-derived preparations (e.g., apheresis or leukapheresis preparations), other body fluids or extracts, cells grown in culture, etc.

[0083] D. Channel The device may contain one or more channels with one or more inlets and one or more outlets. The inlets can be used for the introduction of samples or crude (i.e., unpurified) fluid compositions, buffers, or reagents. The outlets can be used to collect products or as waste outlets. The channels can be about 0.5 to 100 mm wide and about 2-200 mm long, but can also be of different widths and lengths. They can be 1-1000 μm deep, and there can be anywhere from 1 to 100 channels or more. The volume can vary over a very wide range, from a few μl to several ml, and the device can have multiple zones (stages or sections) with different obstacle configurations.

[0084] E. Gap size (edge-to-edge distance between posts or obstacles) The gap size (edge-to-edge distance between posts or obstacles) of the array of obstacles can be from about a few micrometers (e.g., 1-500) micrometers to over 1 millimeter. The obstacles, in some embodiments, can have diameters of 1-3000 micrometers and can have a variety of shapes (circular, triangular, teardrop, diamond, square, rectangular, etc.). The first row of posts can be located close to the inlet (e.g., within 5 μm) or 1 mm or more away.

[0085] F. Stackable Chips A device can include multiple stackable chips. A device can include about 1 to 50 chips. In some examples, a device can have multiple chips arranged in series or parallel, or both. [Example]

[0086] Example The following examples are intended to illustrate, but not limit, the present invention. A normal blood sample was diluted 0.2x and processed on the DLD in normal separation mode (sample run against buffer). The first product fraction collected had the expected concentration (a further 0.28x dilution) based on the input number and inlet-to-outlet DLD device ratio. Midway through the run, the collected product was recirculated to the DLD device as a "wash stream." Various fractions were collected at various time points while continuing to recirculate the DLD product. To obtain recovery values, the final volume and final concentration of the DLD product were compared to the input volume and input concentration of the sample. Net recovery of WBCs after multiple passes was 97.5%, with a 2.9x change in concentration factor from input material to product material (compared to the initial 0.28x change from input to product when the sample was run against running buffer).

[0087] All references cited herein are incorporated by reference. Having fully described the invention, it will be understood by those skilled in the art that the invention can be practiced within a wide range of equivalent conditions, parameters, and the like, without affecting the spirit or scope of the invention or any embodiment thereof.

Claims

1. 1. A method for separating target cells or particles of a predetermined size from a sample containing cells or particles of the predetermined size, comprising: a) Both sample and wash solutions are applied to the microfluidic device at separate inlets, where: i) the wash solution applied to the device is devoid of said target cells or target particles and is devoid of said cells or particles below a predetermined size; ii) the microfluidic device comprises an array of obstacles arranged in rows, wherein each subsequent row of obstacles is laterally shifted relative to the previous row, and the obstacles are arranged to differentially deflect and direct target cells or target particles into a first outlet from which they can be collected as target cell or target particle product, and to direct cells or particles below a predetermined size to a second outlet where they can be collected or discarded as waste; b) performing deterministic lateral displacement (DLD) by flowing a sample and a wash solution through the device, wherein during said DLD, at least a portion of the target cell or target particle product is recirculated one or more times such that all or at least a portion of the wash solution is applied to the device; c) collecting the final product containing the target cells or particles from the first outlet during or at the end of step b). This includes: A method wherein after the target cell or target particle product has been recirculated, the recirculation is stopped and a wash solution is again applied to the microfluidic device.

2. 2. The method of claim 1, wherein the wash solution is water or an aqueous buffer, or water or an aqueous buffer containing: a) a reagent that chemically reacts with cells, particles, or other components in the wash solution; or b) an antibody, carrier, or activator that specifically interacts with target cells or target particles.

3. 3. The method of claim 1 or 2, wherein the sample comprises target cells or stem cells of a predetermined size and cells below the predetermined size.

4. 4. The method of claim 3, wherein the target cells are white blood cells and the cells under a predetermined size are platelets or red blood cells.

5. The method of claim 4, wherein the leukocytes are T cells.

6. 1. A method of producing purified genetically engineered target cells, comprising: a) obtaining a sample containing target cells of a predetermined size and one or more contaminating cells or particles smaller than the predetermined size; b) applying a sample at a first inlet and a wash fluid at a second inlet to a microfluidic device, wherein the microfluidic device comprises an array of obstacles arranged to parallaxically deflect a stream of target cells to a first outlet and contaminating cells or particles smaller than a predetermined size to a second outlet, where the target cells can be collected as a target cell product; c) flowing the sample and wash fluid through the device, wherein the concentration of target cells at a first outlet is determined and at least a portion of the target cells are recirculated from the outlet to replace all or at least a portion of the wash fluid applied to the inlet of the device, said recirculation being continued or repeated until a desired product cell concentration (PC) is achieved; d) upon reaching the PC, directing the stream of target cells out a first outlet into a device where the target cells are transformed or transfected to form genetically engineered target cells; e) flowing the genetically engineered target cells into the device where they are separated from reagents, viruses, or other materials used to transform or transfect the target cells to form purified genetically engineered target cells; f) Either collect the purified genetically engineered target cells or flow the purified genetically engineered target cells to another device where they are further processed before collection. This includes: After the target cells have been recirculated, the recirculation is stopped and the wash solution is again applied to the microfluidic device.

7. The method of claim 6, wherein all steps from applying the cells to the microfluidic device in step b) to collecting the cells are carried out as a single continuous process.

8. 8. The process of claim 6 or 7, wherein the target cells are T lymphocytes.

9. 9. The method of claim 8, wherein the T lymphocytes are genetically engineered to produce a chimeric antigen receptor (CAR) on their surface.

10. The method according to any one of claims 6 to 9, wherein in steps b) and c) the target cells are separated from cells or particles larger or smaller than a predetermined size by DLD.

11. 11. The method of any one of claims 6 to 10, wherein in step e) the device is a microfluidic device and the genetically engineered target cells are separated from reagents, viruses or other materials used to transform or transfect the target cells with DLD.

12. 12. The method of any one of claims 6 to 11, wherein the first outlet comprises or is connected to a valve that can be used to direct the target cells to a conduit that recirculates the product to an inlet of a microfluidic device or that can direct the flow of target cells from the first outlet to a device where the target cells are transformed or transfected to form genetically engineered target cells.

13. 13. The method of claim 12, wherein the valve is configured to electronically respond to concentrations of target cells below PC by directing the target cells to a conduit that recirculates the product to an inlet on the microfluidic device, and to electronically respond to concentrations of target cells above PC by directing the target cells to a device where the target cells are transformed or transfected to form genetically engineered target cells.

14. The method of any one of claims 6 to 13, wherein recirculation with microfluidic processing is the only method used to concentrate the cells or particles.

15. 15. The method of any one of claims 6 to 14, wherein the target cells are not centrifuged during the entire time between obtaining the sample in step a) and collecting the cells in step f).

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