3D Bioreactor Filled Void Structure for Cell Expansion
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Solution Overview
Problem
Current 3D bioreactors for cell expansion and viral vector production lack sufficient surface area and uniformity, leading to cell aggregation, phenotype changes, and inefficient expansion.
Innovation Solution
A three-dimensional bioreactor with non-random voids and internal structures, featuring a continuous interconnected surface area, controlled pore channels, and biocompatible materials, designed to promote monolayer cell growth and reduce aggregation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If conventional 3D bioreactors are used for cell expansion, then cell growth can be achieved, but surface area is insufficient and cell aggregation occurs
Solution Approach 1:
The bioreactor is divided into multiple voids (e.g., 50-200 voids per reactor) with each void containing internal structures (e.g., spheres, cylinders, or porous materials). This segmentation creates numerous distributed surface areas throughout the reactor volume, increasing total surface area while preventing cell aggregation by localizing cells to specific attachment sites within each void.
Solution Approach 2:
Internal structures are nested within the voids of the bioreactor framework. These internal structures (such as spheres, cylinders, or porous materials) are positioned inside the voids to provide additional surface area for cell attachment. The nested configuration maximizes surface area utilization within the available reactor volume while maintaining structural integrity.
2Productivity
If conventional 3D bioreactors are used for viral vector production, then cell expansion can occur, but phenotype changes and aggregation are observed
Solution Approach 1:
The bioreactor provides localized quality through uniform internal structures within each void that create consistent micro-environments for cell attachment and growth. This local quality ensures uniform nutrient distribution and cell density across all voids, preventing phenotype changes while maintaining high productivity through controlled cell expansion.
Solution Approach 2:
The bioreactor utilizes controlled parameter changes in void diameter (0.5-5 mm), internal structure size (0.1-2 mm), and pore channel dimensions to optimize cell expansion while maintaining phenotype stability. By carefully controlling these geometric parameters, the system achieves high productivity without inducing aggregation or phenotype changes.
3Area of stationary object
If non-random voids with internal structures are implemented, then surface area increases, but manufacturing precision requirements increase
Solution Approach 1:
The bioreactor employs porous materials with controlled pore sizes and distributions to create the void structures. These porous materials provide inherent uniformity in pore dimensions (e.g., 0.1-2 mm pores) while maintaining high surface area. The porous structure naturally distributes cells uniformly across the surface area without requiring extremely tight manufacturing tolerances.
Solution Approach 2:
The bioreactor combines different materials with complementary properties to achieve both high surface area and manufacturability. The framework uses biocompatible materials (e.g., polystyrene, polycarbonate, or metal alloys) that can be manufactured with standard precision, while the internal structures use materials that provide optimal surface area and cell attachment properties.
Data Source
AI summary
The design, fabrication and applications of a three-dimensional (3D) bioreactor with filled void structure. The bioreactor comprises non-random voids filled with a non-random internal structure where the voids are interconnected through non-random pore channels. The 3D bioreactor provides a three-dimensional surface area for cell adherence and growth.