Robotic Cell Processing Workcell With Modular Cartridges
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Solution Overview
Problem
Conventional cell product manufacturing processes are cumbersome, expensive, and prone to human error due to reliance on manual operations in biosafety cabinets and clean rooms, lacking end-to-end process flexibility, robustness, and scalability, and current automated systems are limited by inflexible instrumentation and high contamination risk.
Innovation Solution
A system comprising a robot and multiple instruments within a workcell that processes cell products in a cartridge, enabling automated, sterile, and flexible manufacturing with reduced footprint, using a cartridge with integrated modules for various cell processing steps, and a fluid connector for sterile liquid transfer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual operations are performed in biosafety cabinets and clean rooms, then cell processing can be conducted, but the process becomes cumbersome, expensive, and prone to human error
Solution Approach 1:
The system divides the cell processing workflow into discrete modules contained within a cartridge (e.g., cell culture chamber, separation module, collection chamber). Each module performs a specific function, allowing the complex process to be segmented into manageable, automated steps that reduce human error while maintaining reliability.
Solution Approach 2:
The automated cell processing system performs operations independently without continuous human intervention. The robot autonomously manipulates the cartridge, instruments automatically execute processing steps, and the system self-manages the workflow from cell input to final product collection, eliminating reliance on manual operations in clean rooms.
2Ease of operation
If automated systems are implemented, then labor costs are reduced, but current automated systems lack process flexibility and have high contamination risk
Solution Approach 1:
The system employs programmable control that allows processing protocols to be dynamically adjusted and reconfigured. The robot and instruments can execute different sequences of operations based on programmed instructions, enabling the same automated system to adapt to various cell processing requirements while maintaining sterility and reducing contamination risk.
Solution Approach 2:
The automated system is designed with multi-functional instruments and a versatile cartridge architecture that can handle different cell types, processing steps, and product formulations. This universal design allows a single automated platform to perform diverse cell processing operations, maintaining both automation benefits and process flexibility.
3Productivity
If conventional manual processes are used, then process steps can be performed, but the process duration is extended to several days or weeks
Solution Approach 1:
The automated system enables continuous processing without the interruptions inherent in manual operations. The robot continuously manipulates the cartridge through different instruments in sequence, and multiple cartridges can be processed in parallel, eliminating idle time between steps and significantly reducing overall process duration from weeks to hours or days.
Solution Approach 2:
The cartridge is pre-configured with all necessary modules, reagents, and chambers before entering the automated system. Cell input, processing steps, and collection are pre-planned and programmed, allowing the system to execute the complete process continuously without pauses for manual reconfiguration, thereby maximizing throughput and minimizing process time.
4Extent of automation
If pre-configured instrumentation and tubing sets are used, then automation is achieved, but operational flexibility is limited and process failure risk increases
Solution Approach 1:
Instead of using fixed, pre-configured tubing sets, the system segments the fluid handling into modular cartridge components with standardized interfaces. The robot dynamically connects and manipulates these modular sections, providing automation while maintaining the flexibility to reconfigure processing pathways as needed without being constrained by rigid pre-configured instrumentation.
Data Source
AI summary
Disclosed herein are cell processing systems, devices, and methods thereof. A system for cell processing may comprise a plurality of instruments each independently configured to perform one or more cell processing operations upon a cartridge, and a robot capable of moving the cartridge between each of the plurality of instruments.