Modular Stackable Bioreactor Design for Scalable Tissue Engineering
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Solution Overview
Problem
Current tissue engineering bioreactors are not designed for large-scale commercial manufacturing and are limited by static scaling and container size, hindering efficient cell culture expansion.
Innovation Solution
A scalable, modular bioreactor system with stackable containers and a motion control system that tilts or rocks containers, allowing dynamic flow and temperature control, along with a temperature regulation system and gas management, enabling easy scaling and increased cell culture viability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional bioreactors are used for tissue engineering, then cell culture can be maintained, but scaling to large-scale commercial manufacturing is not feasible
Solution Approach 1:
The bioreactor system is divided into multiple independent modules (container assemblies with trays) that can be individually manufactured, operated, and scaled. Each module contains cell culture containers on trays that can be stacked vertically, allowing the system to achieve large-scale production capacity through modular replication rather than scaling up single complex units.
Solution Approach 2:
Multiple cell culture containers are nested within trays, and multiple trays are stacked vertically within each module. This nested arrangement maximizes the use of vertical space and allows high-density cell culture capacity within a compact footprint, enabling large-scale production without proportionally increasing device complexity.
2Productivity
If bioreactors are designed for static operation, then device simplicity is maintained, but cell culture expansion efficiency is limited
Solution Approach 1:
The bioreactor system incorporates motion control capabilities that allow trays to be dynamically tilted and rocked during operation. This dynamic movement creates fluid flow patterns that enhance mass transfer and cell culture efficiency, improving productivity without requiring complete system redesign.
Solution Approach 2:
The motion control system implements periodic tilting and rocking cycles of the trays, creating intermittent fluid flow that promotes cell culture expansion. This periodic action alternates between static and dynamic states, maintaining cell viability while enhancing nutrient distribution and waste removal.
3Adaptability or versatility
If modular stackable containers are implemented, then scalability is improved, but device complexity increases
Solution Approach 1:
The modular container assemblies are designed with universal interfaces and standardized configurations that allow them to function independently or be stacked in various combinations. Each module can operate autonomously or be integrated into larger configurations, providing flexibility for scaling from small to large-scale production without requiring different device designs.
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
Facilitates large-scale commercial manufacturing of cell cultures by enhancing viability and scalability, allowing for dynamic fluid flow and temperature regulation, and supporting efficient cell growth across various sizes and configurations.
Implementation Method 1
an angular raising and lowering can create a wave in a wave in a cell culture medium within said cell culturing container
Implementation Method 2
a system can further comprise a temperature control system. A temperature control system can be configured to heat or cool at least a portion of a system to a temperature of from about −200 degrees Celsius to about 200 degrees Celsius
Data Source
AI summary
Disclosed herein are scalable, modular bioreactor systems for efficient preparation of cell-based tissues. Also disclosed herein are methods, compositions, and apparatuses for preparing scaffolds.