Optical Cell Culture Cassette Automation for Sterile Cell Removal
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Solution Overview
Problem
Current artisanal methods for manufacturing autologous iPSC-derived cell therapies are time-consuming, expensive, and face scalability challenges, making them economically unfeasible and difficult to achieve regulatory approval due to issues with cost-effectiveness and volume production.
Innovation Solution
A cell manufacturing platform utilizing optical bioprocesses with an optical engine for imaging and cell removal, integrated with a robotic system and AI for automated cell culture management, enabling scalable and efficient production of iPSCs and differentiated cells in closed, sterile cassettes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual artisanal methods are used for cell manufacturing, then quality control and precision can be maintained, but productivity is low and the process is time-consuming
Solution Approach 1:
The patent replaces manual mechanical operations with an optical system that uses light to image and manipulate cells. The optical engine captures images of cells in culture and uses optical forces to remove cells from the culture surface, eliminating the need for manual picking and transfer operations while maintaining precision through optical feedback control.
Solution Approach 2:
The system enables cells to be automatically identified, imaged, and removed through the optical engine without human intervention. The optical system self-regulates by capturing images, analyzing cell positions, and applying optical forces to remove target cells, creating an autonomous cell manufacturing process that maintains quality control while dramatically improving productivity.
2Manufacturing precision
If manual cell picking and transfer operations are performed, then cell manipulation precision can be achieved, but the process takes 10-12 weeks and is labor-intensive
Solution Approach 1:
The patent replaces manual mechanical picking and transfer operations with an optical system that uses light fields to manipulate cells. The optical engine captures images of cells in real-time and applies optical forces to remove cells directly from the culture surface, eliminating the need for physical manipulation with tools and reducing the process from 10-12 weeks to a much shorter duration.
Solution Approach 2:
The optical engine operates continuously to image and remove cells without interruption. Unlike manual operations that require stopping, transferring, and resetting, the optical system maintains continuous operation by rapidly scanning the culture surface, identifying target cells, and removing them in sequence, dramatically reducing total manufacturing time while maintaining precision.
3Productivity
If automated systems are introduced to improve productivity, then manufacturing speed increases, but device complexity and cost increase
Solution Approach 1:
The optical engine serves multiple functions within a single device: it images cells for identification, manipulates cells through optical forces, and removes cells from culture. This multi-functionality consolidates what would otherwise require separate systems for imaging, manipulation, and removal into one integrated platform, increasing productivity while limiting the growth of overall system complexity.
Solution Approach 2:
The optical field acts as an intermediary between the control system and the cells. Rather than requiring complex mechanical manipulators or robotic arms to physically handle cells, the system uses light as a non-contact intermediary to transfer energy and momentum to cells for manipulation and removal, simplifying the mechanical complexity of the system while maintaining high productivity.
4Reliability
If closed sterile cassettes are used to maintain sterility, then contamination risk is reduced, but the optical engine must operate through transparent barriers which limits optical power
Solution Approach 1:
The system optimizes the optical properties of the cassette materials by selecting transparent materials with specific transmission characteristics for the laser wavelength used. By changing the parameters of the optical barrier (material composition, thickness, coating), the system achieves sufficient light transmission through the sterile barrier to enable effective optical cell removal while maintaining sterility.
Solution Approach 2:
The optical engine creates an optical pathway through the transparent cassette barrier, effectively copying the function of direct optical access while maintaining the physical barrier. The light field is transmitted through the transparent cassette wall, allowing the optical engine to manipulate cells on the other side of the barrier without direct contact, thus maintaining sterility while enabling full optical functionality.
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
The platform allows for high-throughput, cost-effective, and automated production of iPSCs and differentiated cells, maintaining sterility and reducing manual intervention, thus addressing scalability and regulatory challenges.
Implementation Method 1
an optical engine configured to: capture images of the cell culture
Implementation Method 2
optically remove cells from the cell culture
Data Source
AI summary
Systems and methods are disclosed for enabling optical bioprocesses in cell manufacturing. A cell manufacturing platform comprises a cell culture cassette supporting a cell culture; an optical engine configured to: capture images of the cell culture; and optically remove cells from the cell culture; and wherein the cell culture cassette remains stationary and the optical engine moves relative to the cell culture cassette to capture the images and to remove cells.