3D Printing of Bioreactors: a New Horizon for Bioprocess Development
Researchers develop a 3D-printed small-scale, single-use bioreactor that features real-time monitoring of cell growth.
The continuous development of upstream bioprocesses requires cost-effective and customizable bioreactors for optimizing production processes. Leveraging the recent advances in additive manufacturing, this research introduces a small-scale 3D printed bioreactor designed for both mammalian and microbial cultivations. The bioreactor boasts a 90 mL working volume and incorporates inline pH and dissolved oxygen probes, along with a levitating magnetic stirrer. A unique feature is the integration of aeration channels and a sampling port directly into the vessel walls. Additionally, a 3D printed customizable optical biomass sensor enhances the bioreactor's functionality.
The study evaluated the bioreactor's performance through technical characterization and proof-of-concept cultivations. Results indicated that the mixing time and oxygen mass transfer were adequate for cultivating both mammalian and microbial cells at high densities. For instance, an Escherichia coli fed-batch cultivation achieved an impressive maximum OD600 of 204. In another demonstration, a fed-batch cultivation of a Chinese hamster ovary cell line producing IgG antibodies achieved a peak viable cell density of 10.2 × 106 cells mL−1 and a maximum product titer of 2.75 g L−1.
A notable aspect of the bioreactor is its 3D printed customizable optical biomass sensor, allowing real-time monitoring of cell growth. By employing a three-parameter fit, the inline biomass signal was successfully correlated to corresponding offline values with satisfactory accuracy. This innovation holds promise for advancing the efficiency of upstream bioprocessing by providing a cost-effective and flexible tool for investigating and optimizing production processes.
