Scaffold Bioreactor with Segmented Trays for Structured Tissue
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Solution Overview
Problem
Current bioreactor systems are not suitable for large-scale, cost-effective production of structured cultivated meat products due to challenges with cell infiltration, nutrient and oxygen diffusion, scaffold design, cell alignment, and medium conservation, particularly in achieving high tissue density and structure while maintaining scalability and reducing operational costs.
Innovation Solution
A scaffold bioreactor system comprising a vessel with arrayed scaffold trays, a recirculation media tank, and circulation manifolds that allows for efficient nutrient and oxygen delivery, waste removal, and media recirculation, eliminating the need for moving parts and enabling scalable production of thick, dense, and structured tissues without increasing production costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If stirred tanks are used to produce unstructured meat, then large-scale production is achieved, but structured tissue formation is prevented
Solution Approach 1:
The bioreactor is segmented into multiple trays arranged in a multi-layer configuration, with each tray containing scaffolds that provide structured surfaces for tissue formation. This segmentation allows the system to maintain large-scale production capacity while enabling structured tissue development on individual tray surfaces, resolving the contradiction between production scale and tissue structure.
2Manufacturing precision
If hollow fiber bioreactors are used to produce structured tissue, then whole-cut meat production is enabled, but operational costs increase and scalability is limited
Solution Approach 1:
The tray-based bioreactor design serves multiple functions: it provides structured scaffold surfaces for tissue formation, enables large-scale production through multi-tray arrays, facilitates media distribution via manifolds, and allows for easy scalability by adding or removing trays. This multi-functionality resolves the contradiction between tissue structure and scalability by integrating all required capabilities into a single versatile platform.
3Manufacturing precision
If multi-layer scaffold trays are implemented, then structured tissue production is enabled, but system complexity increases
Solution Approach 1:
The bioreactor system is divided into independent, modular trays that can be individually manufactured, assembled, and maintained. Each tray contains scaffolds arranged in specific configurations for structured tissue production, while the overall system complexity is managed through standardization of tray components and interfaces, allowing complex tissue structure capabilities without proportionally increasing overall system complexity.
4Loss of substance
If media recirculation is implemented, then medium conservation is achieved, but nutrient and oxygen diffusion efficiency may be reduced
Solution Approach 1:
The manifold system distributes media to different trays and regions within trays with locally optimized flow characteristics. Media recirculation is implemented with localized delivery points that ensure adequate nutrient and oxygen diffusion to tissue structures in each tray, while overall medium conservation is achieved through recirculation. This local optimization resolves the contradiction by ensuring that recirculation does not compromise local diffusion efficiency.
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 scaffold bioreactor system supports high-volume production of whole-cut meat by ensuring efficient nutrient and oxygen delivery, waste removal, and medium conservation, reducing scale-up risks and accelerating industrialization while maintaining aseptic conditions and reducing operational costs.
Implementation Method 1
circulation manifolds that allows for efficient nutrient and oxygen delivery, waste removal, and media recirculation
Implementation Method 2
waste removal, and media recirculation, eliminating the need for moving parts
Data Source
AI summary
A system for culturing cells includes a bioreactor including a scaffold on which the cells tend to adhere. The system further includes a circulatory system that intermittently flows fluid over the scaffold.