3D Printed In-Situ Bioreactor Probes for Real-Time NIR Monitoring
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Solution Overview
Problem
Current bioprocessing technologies face challenges with the high cost and complexity of in-situ probes for monitoring bioreactors, particularly due to demanding geometries and the need for expensive, time-consuming calibration and sterilization processes, which limits the frequency and accuracy of real-time monitoring.
Innovation Solution
The development of 3D printed in-situ probes that utilize spectroscopic analysis, such as near-infrared absorption spectroscopy, with integrated optical components and thin transmission sections, allowing for cost-effective fabrication and single-use applications, reducing assembly complexities and minimizing exposure of bioreactor contents to external conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional in-situ probes with complex geometries are used for spectroscopic monitoring, then measurement precision is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent changes the manufacturing method from traditional machining to 3D printing, enabling complex geometries to be fabricated with simple parameter adjustments. This allows maintaining measurement precision while reducing manufacturing complexity and cost through digital modeling and additive manufacturing processes.
Solution Approach 2:
The patent implements single-use disposable probes made through 3D printing, eliminating the need for complex sterilization and calibration procedures. These inexpensive disposable probes maintain measurement precision while dramatically reducing device complexity in terms of maintenance and operational requirements.
2Reliability
If traditional sterilization and calibration procedures are applied to probes, then reliability is improved, but loss of time and productivity decrease
Solution Approach 1:
The patent employs single-use disposable probes that are pre-sterilized during manufacturing through 3D printing. Each probe is used once and then discarded, eliminating time-consuming sterilization and calibration steps while maintaining reliability through consistent factory-controlled manufacturing and quality assurance.
Solution Approach 2:
The patent performs sterilization and quality validation during the 3D printing manufacturing process itself, before the probe reaches the user. This preliminary action ensures reliability is established upfront, eliminating the need for time-consuming post-manufacturing sterilization and calibration procedures.
3Strength
If stainless steel probes are used for spectroscopic analysis, then strength and durability are improved, but ease of manufacture and cost worsen
Solution Approach 1:
The patent uses biocompatible polymers and resins specifically selected for their optical transparency and mechanical properties suitable for spectroscopic applications. These composite materials provide sufficient strength for single-use applications while enabling cost-effective 3D printing manufacturing, replacing expensive stainless steel fabrication.
Solution Approach 2:
The patent transitions from durable stainless steel probes to inexpensive single-use polymer probes manufactured by 3D printing. This approach sacrifices long-term durability for dramatically reduced manufacturing cost and complexity, with each disposable probe maintaining sufficient strength for its intended single-use lifecycle.
4Measurement precision
If sampling frequency is increased for better process control, then measurement precision is improved, but loss of time and operational costs increase
Solution Approach 1:
The patent's disposable probes enable rapid exchange between samples, allowing high sampling frequencies without time-consuming sterilization or calibration between measurements. Each probe can be quickly inserted and removed, enabling frequent sampling that improves process control accuracy without proportionally increasing time loss.
Solution Approach 2:
The patent replaces mechanical sampling and offline analysis systems with in-situ spectroscopic monitoring using 3D printed probes. This substitution enables continuous real-time measurement at high frequency without the time losses associated with physical sample collection, transport, and laboratory analysis.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables real-time, non-destructive monitoring of bioreactor contents with improved sampling frequency and reduced operational costs, facilitating more efficient process control and optimization without the need for traditional windows or extensive sterilization procedures.
Implementation Method 1
Among these, probably the most common is absorption spectroscopy. Incident light excites electrons of the analyte from a low energy ground state into a high energy, excited state, and the energy can be absorbed by both non-bonding n-electrons and π-electrons within a molecular orbital.
Implementation Method 2
Specific implementations rely on near infrared (NIR) absorption spectroscopy.
Data Source
AI summary
A device for monitoring a bioreactor is designed for in-situ analysis, e.g., by NIR. The device is configured for maintaining a sample detection region in the reactor medium and can include two or more components, at least one of which is fabricated additively. In an example, a light beam propagates along a free space optical path, passes through a thin 3D printed layer and traverses the sample detection region, where it becomes modulated or modified by interactions with analytes present in the bioreactor. The transmitted light reaches and passes through another thin 3D printed layer and is detected by a photodetector, internal to the device. The electrical signal from the photodetector can be directed to an analyzer via electrical connections. The device or a component thereof can be designed for single use applications.