Continuous Flow Microbioreactor With Gyroid Modules for Consistent Scale-Up
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Solution Overview
Problem
Existing bioreactors face challenges in scalability, cost, and consistency of cell growth and product production, often resulting in suboptimal conditions and population heterogeneity, which affect the quality, purity, and yield of bioproducts.
Innovation Solution
The development of a bioreactor system comprising minimodules with double gyroid structures, interconnected microchannels, and modular configurations that allow for flexible and scalable cell growth conditions, including cell chip, sandbox, and production bioreactors, along with sensors and control systems for monitoring and adjusting environmental parameters.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If large scale bioreactors are used for production, then productivity increases, but manufacturing precision and growth condition consistency deteriorate
Solution Approach 1:
The bioreactor system is divided into multiple minimodules (e.g., 96 minimodules) that can be connected in series or parallel configurations. Each minimodule contains microchannels with controlled dimensions (e.g., 200-500 micrometers) that maintain consistent flow dynamics and growth conditions even at large scale. This segmentation allows the system to achieve high productivity through parallel processing while maintaining manufacturing precision through standardized module design and controlled microenvironment in each minimodule.
2Productivity
If large bioreactors are used, then productivity increases, but device complexity and capital investment increase
Solution Approach 1:
The system uses standardized minimodules that can be easily assembled and disassembled. Each minimodule is a self-contained unit with integrated microchannels and growth chambers, reducing the complexity of managing large-scale systems. The modular design allows for scalable production (e.g., connecting 96 minimodules) without proportionally increasing operational complexity, as each module follows the same design principles and can be managed independently.
Solution Approach 2:
The invention transitions from traditional two-dimensional surface growth to three-dimensional growth within microchannels. The microchannels provide controlled 3D environments with specific dimensions (e.g., 200-500 micrometers) that enable consistent growth conditions. This dimensional change allows for higher cell density and productivity within each minimodule, reducing the number of modules needed for a given production scale, thereby simplifying the overall system.
3Manufacturing precision
If small scale growth chambers are used, then manufacturing precision and growth condition consistency improve, but productivity decreases
Solution Approach 1:
The system maintains the advantages of small-scale growth chambers by using multiple minimodules in parallel or series configurations. Each minimodule preserves the controlled microenvironment necessary for consistent growth conditions, while the collective array of minimodules achieves high productivity through additive scaling. For example, connecting 96 minimodules provides both the precision of small chambers and the throughput of large-scale production.
Solution Approach 2:
The invention combines multiple small-scale minimodules into a unified bioreactor system that functions as a single high-productivity unit. The minimodules are fluidically connected through standardized interfaces, allowing them to operate in parallel (increasing productivity) or in series (enabling staged growth conditions). This merging approach maintains the manufacturing precision of individual small chambers while achieving the productivity of large-scale systems.
4Productivity
If large bioreactors are used, then productivity increases, but measurement precision for individual cell conditions deteriorates
Solution Approach 1:
The minimodule design creates discrete, isolated microenvironments that facilitate precise monitoring of individual cell conditions. Each minimodule acts as an independent experimental unit with controlled dimensions, allowing for targeted measurement and analysis. This segmentation enables researchers to study cellular behavior at the individual or small-population level even within a large-scale production system, maintaining measurement precision while achieving high productivity through the multiplicity of minimodules.
Data Source
AI summary
The present disclosure contemplates components, systems and methods for bioreactors that may be employed for producing and maintaining cells, optimizing cell growth and production of products from such cells, and for producing and isolating cells and products made by such cells. The systems, components and methods herein address the scale, cost, efficiency and consistency and are suitable for bespoke cell and bioproduct production.