Purification of monoclonal antibodies using novel 3D printed ordered stationary phases.

3D printing offers the unprecedented ability to fabricate chromatography stationary phases with bespoke 3D morphology as opposed to traditional packed beds of spherical beads. The restricted range of printable materials compatible with chromatography is considered a setback for its industrial implementation. Recently, we proposed a novel ink that exhibits favourable printing performance (printing time ∼100 mL/h, resolution ∼200 µm) and broadens the possibilities for a range of chromatography applications thanks to its customisable surface chemistry. In this work, this ink was used to fabricate 3D printed ordered columns with 300 µm channels for the capture and polishing of therapeutic monoclonal antibodies. The columns were initially assessed for leachables and extractables, revealing no material propensity for leaching. Columns were then functionalised with protein A and SO3 ligands to obtain affinity and strong cation exchangers, respectively. 3D printed protein A columns showed >85 % IgG recovery from harvested cell culture fluid with purities above 98 %. Column reusability was evaluated over 20 cycles showing unaffected performance. Eluate samples were analysed for co-eluted protein A fragments, host cell protein and aggregates. Results demonstrate excellent HCP clearance (logarithmic reduction value of > 2.5) and protein A leakage in the range of commercial affinity resins (<100 ng/mg). SO3 functionalised columns employed for polishing achieved removal of leaked Protein A (down to 10 ng/mg) to meet regulatory expectations of product purity. This work is the first implementation of 3D printed columns for mAb purification and provides strong evidence for their potential in industrial bioseparations.

Development, characterization and application of 3D printed adsorbents for in situ recovery of taxadiene from microbial cultivations.

Microbial cell factories are an attractive alternative to produce high-value natural products using sustainable processes. However, product recovery is one of the main challenges to reduce production cost and make these technologies economically interesting. In this work, new resins were formulated to 3D print hydrophobic adsorbents for the recovery of biologics from microbial cultivations. Benzyl methacrylate (BEMA) and butyl methacrylate (BUMA) were selected as functional monomers suitable for the adsorption of hydrophobic compounds. Pore morphology was tailored through the inclusion of pore forming agents (porogens) in the resin. Different porogens and porogen concentrations were evaluated resulting in materials with different porous networks. Sudan 1 and the anticancer drug paclitaxel were employed as model compounds to test the adsorption performance of hydrophobic and terpene molecules onto the developed 3D printed materials. The material with greatest adsorption capacity was obtained using BEMA monomer with 40 % (v/v) porogen (BEMA40). The performance of BEMA40 to recover taxadiene from small-scale (5 mL) Saccharomyces cerevisiae cultivations was tested and compared with commercial Diaion HP-20 beads. Taxadiene titres on BEMA40 (46 ± 2 mg/L) and Diaion HP-20 (54 ± 4 mg/L) were comparable, with no taxadiene detected in the cells and cell-free media, suggesting near 100 % taxadiene partition on the adsorbents. Compared to commercial beads, 3D printed adsorbents can be customized with adjustments in the resin formulation, are well adaptable to diverse bioreactor types, do not clog sampling ports and columns and are easier to handle during post processing. The results of this work demonstrate the potential of 3D printing to fabricate hydrophobic interaction adsorbent materials and their application in the recovery of biological products.

In situ recovery of taxadiene using solid adsorption in cultivations with Saccharomyces cerevisiae.

In this study, an engineered strain of Saccharomyces cerevisiae was used to produce taxadiene, a precursor in the biosynthetic pathway of the anticancer drug paclitaxel. Taxadiene was recovered in situ with the polymeric adsorbent Diaion © HP-20. Here we tested two bioreactor configurations and adsorbent concentrations to maximize the production and recovery of taxadiene. An external recovery configuration (ERC) was performed with the integration of an expanded bed adsorption column, whereas the internal recovery configuration (IRC) consisted in dispersed beads inside the bioreactor vessel. Taxadiene titers recovered in IRC were higher to ERC by 3.4 and 3.5 fold by using 3% and 12% (w/v) adsorbent concentration respectively. On the other hand, cell growth kinetics were faster in ERC which represents an advantage in productivity (mg of taxadiene/L*h). High resin bead concentration (12% w/v) improved the partition of taxadiene onto the beads up to 98%. This result represents an advantage over previous studies using a 3% resin concentration where the partition of taxadiene on the beads was around 50%. This work highlights the potential of in situ product recovery to improve product partition, reduce processing steps and promote cell growth. Nevertheless, a careful design of bioreactor configuration and process conditions is critical.

In silico screening of nanoporous materials for urea removal in hemodialysis applications.

The design of miniaturized hemodialysis devices, such as wearable artificial kidneys, requires regeneration of the dialysate stream to remove uremic toxins from water. Adsorption has the potential to capture such molecules, but conventional adsorbents have low urea/water selectivity. In this work, we performed a comprehensive computational study of 560 porous crystalline adsorbents comprising mainly covalent organic frameworks (COFs), as well as some siliceous zeolites, metal organic frameworks (MOFs) and graphitic materials. An initial screening using Widom insertion method assessed the excess chemical potential at infinite dilution for water and urea at 310 K, providing information on the strength and selectivity of urea adsorption. From such analysis it was observed that urea adsorption and urea/water selectivity increased strongly with fluorine content in COFs, while other compositional or structural parameters did not correlate with material performance. Two COFs, namely COF-F6 and Tf-DHzDPr were explored further through Molecular Dynamics simulations. The results agree with those of the Widom method and allow to identify the urea binding sites, the contribution of electrostatic and van der Waals interactions, and the position of preferential urea-urea and urea-framework interactions. This study paves the way for a well-informed experimental campaign and accelerates the development of novel sorbents for urea removal, ultimately advancing on the path to achieve wearable artificial kidneys.

Evaluating 3D-printed bioseparation structures using multi-length scale tomography.

X-ray computed tomography was applied in imaging 3D-printed gyroids used for bioseparation in order to visualize and characterize structures from the entire geometry down to individual nanopores. Methacrylate prints were fabricated with feature sizes of 500 µm, 300 µm, and 200 µm, with the material phase exhibiting a porous substructure in all cases. Two X-ray scanners achieved pixel sizes from 5 µm to 16 nm to produce digital representations of samples across multiple length scales as the basis for geometric analysis and flow simulation. At the gyroid scale, imaged samples were visually compared to the original computed-aided designs to analyze printing fidelity across all feature sizes. An individual 500 µm feature, part of the overall gyroid structure, was compared and overlaid between design and imaged volumes, identifying individual printed layers. Internal subvolumes of all feature sizes were segmented into material and void phases for permeable flow analysis. Small pieces of 3D-printed material were optimized for nanotomographic imaging at a pixel size of 63 nm, with all three gyroid samples exhibiting similar geometric characteristics when measured. An average porosity of 45% was obtained that was within the expected design range, and a tortuosity factor of 2.52 was measured. Applying a voidage network map enabled the size, location, and connectivity of pores to be identified, obtaining an average pore size of 793 nm. Using Avizo XLAB at a bulk diffusivity of 7.00 × 10-11 m2s-1 resulted in a simulated material diffusivity of 2.17 × 10-11 m2s-1 ± 0.16 × 10-11 m2s-1.

Prediction of the performance of pre-packed purification columns through machine learning.

Pre-packed columns have been increasingly used in process development and biomanufacturing thanks to their ease of use and consistency. Traditionally, packing quality is predicted through rate models, which require extensive calibration efforts through independent experiments to determine relevant mass transfer and kinetic rate constants. Here we propose machine learning as a complementary predictive tool for column performance. A machine learning algorithm, extreme gradient boosting, was applied to a large data set of packing quality (plate height and asymmetry) for pre-packed columns as a function of quantitative parameters (column length, column diameter, and particle size) and qualitative attributes (backbone and functional mode). The machine learning model offered excellent predictive capabilities for the plate height and the asymmetry (90 and 93%, respectively), with packing quality strongly influenced by backbone (∼70% relative importance) and functional mode (∼15% relative importance), well above all other quantitative column parameters. The results highlight the ability of machine learning to provide reliable predictions of column performance from simple, generic parameters, including strategic qualitative parameters such as backbone and functionality, usually excluded from quantitative considerations. Our results will guide further efforts in column optimization, for example, by focusing on improvements of backbone and functional mode to obtain optimized packings.

Flexible material formulations for 3D printing of ordered porous beds with applications in bioprocess engineering.

BACKGROUND: 3D printing is revolutioning many industrial sectors and has the potential to enhance also the biotechnology and bioprocessing fields. Here, we propose a new flexible material formulation to 3D print support matrices with complex, perfectly ordered morphology and with tuneable properties to suit a range of applications in bioprocess engineering. FINDINGS: Supports were fabricated using functional monomers as the key ingredients, enabling matrices with bespoke chemistry, such as charged groups, chemical moieties for further functionalization, and hydrophobic/hydrophilic groups. Other ingredients, e.g. crosslinkers and porogens, can be employed to fabricate supports with diverse characteristics of their porous network, providing an opportunity to further regulate the mechanical and mass transfer properties of the supports. Through this approach, we fabricated and demonstrated the operation of Schoen gyroid columns with (I) positive and negative charges for ion exchange chromatography, (II) enzyme bioreactors with immobilized trypsin to catalyse hydrolysis, and (III) bacterial biofilm bioreactors for fuel desulphurization. CONCLUSIONS: This study demonstrates a simple, cost-effective, and flexible fabrication of customized 3D printed supports for different biotechnology and bioengineering applications.

Experimental investigation and mass transfer modelling of 3D printed monolithic cation exchangers.

3D printing has recently found application in chromatography as a means to create ordered stationary phases with improved separation efficiency. Currently, 3D printed stationary phases are limited by the lack of 3D printing materials suitable for chromatographic applications, and require a strict compromise in terms of desired resolution, model size and the associated print time. Modelling of mass transfer in 3D printed monoliths is also fundamental to understand and further optimise separation performance of 3D printed stationary phases. In this work, a novel 3D printing material was formulated and employed to fabricate monolithic cation exchangers (CEXs) with carboxyl functionalities. CEXs were printed with ligand densities of 0.7, 1.4, 2.1 and 2.8 mmol/g and used in batch adsorption experiments with lysozyme as model protein. All CEXs demonstrated high binding strength towards lysozyme, with maximum binding capacities of up to 108 mg/mL. The experimental results were described using mass transfer models based on lumped pore diffusion and lumped solid diffusion mechanisms adapted to reflect the complex geometry of the 3D printed monoliths. An exact 3D model as well as less computationally demanding 1D and 2D approximations were evaluated in terms of their quality to capture the experimental trend of batch adsorption kinetic data. Overall, the model results indicate that mass transfer in the fabricated CEXs is mostly controlled by pore diffusion at high protein concentrations in the mobile phase, with solid diffusion becoming important at low protein concentrations. Also, the kinetic data were approximated equally well by both the full 3D model as well as the 2D approximation, indicating leaner mathematical models of lower dimensionality can be employed to describe mass transfer in complex three dimensional geometries. We believe this work will help spur the development of 3D printable materials for separations and aid in the development of quantitative platforms to evaluate and optimise the performance of 3D printed monoliths.

Demonstration of protein capture and separation using three-dimensional printed anion exchange monoliths fabricated in one-step.

Three-dimensional printing applications in separation science are currently limited by the lack of materials compatible with chromatographic operations and three-dimensional printing technologies. In this work, we propose a new material for Digital Light Processing printing to fabricate functional ion exchange monoliths in a single step. Through copolymerization of the bifunctional monomer [2-(acryloyloxy)ethyl] trimethylammonium chloride, monolithic structures with quaternary amine ligands were fabricated. The novel formulation was optimized in terms of protein binding and recovery, microporous structure, and its swelling susceptibility by increasing its cross-link density and employing cyclohexanol and dodecanol as pore forming agents. In static conditions, the material demonstrated a maximum binding capacity of 104.2 ± 10.6 mg/mL for bovine serum albumin, in line with commercially available materials. Its anion exchange behavior was validated by separating bovine serum albumin and myoglobin on a monolithic bed with Schoen gyroid morphology. The same column geometry was tested for the purification of C-phycocyanin from clarified as well as cell-laden Arthrospira platensis feedstocks. This represents the first demonstration of one-step printed stationary phases to capture proteins directly from solid-laden feedstocks. We believe that the material presented here represents a significant improvement towards implementation of three-dimensional printed chromatography media in the field of separation science.

Numerical Elucidation of Flow and Dispersion in Ordered Packed Beds: Nonspherical Polygons and the Effect of Particle Overlap on Chromatographic Performance.

Spherical particles are widely considered as the benchmark stationary phase for preparative and analytical chromatography. Although this has proven true for randomly packed beds in the past, we challenge this paradigm for ordered packings, the fabrication of which are now feasible through additive manufacturing (3D printing). Using computational fluid dynamics (Lattice Boltzmann Method) this work shows that nonspherical particles can both reduce mobile-phase band broadening and increase permeability compared with spheres in ordered packed beds. In practice, ordered packed beds can only remain physically stable if the particles are fused to form a contiguous matrix, thus creating a positional overlap at the points of fusion between what would otherwise be discrete particles. Overlap is shown to decrease performance of ordered packed beds in all observed cases, thus we recommend it should be kept to the minimum extent necessary to ensure physical stability. Finally, we introduce a metric to estimate column performance, the mean deviated velocity, a quantitative description of the spread of the velocity field in the column. This metric appears to be a good indicator of mobile-phase dispersion in ordered packed bed media, including overlapped beds, and is a useful tool for screening new stationary-phase morphologies without having to perform computationally expensive simulations.

Analysis of the Effect of Processing Conditions on Physical Properties of Thermally Set Cellulose Hydrogels.

Cellulose-based hydrogels were prepared by dissolving cellulose in aqueous sodium hydroxide (NaOH)/urea solutions and casting it into complex shapes by the use of sacrificial templates followed by thermal gelation of the solution. Both the gelling temperatures used (40⁻80 °C), as well as the method of heating by either induction in the form of a water bath and hot press or radiation by microwaves could be shown to have a significant effect on the compressive strength and modulus of the prepared hydrogels. Lower gelling temperatures and shorter heating times were found to result in stronger and stiffer gels. Both the effect of physical cross-linking via the introduction of additional non-dissolving cellulosic material, as well as chemical cross-linking by the introduction of epichlorohydrin (ECH), and a combination of both applied during the gelation process could be shown to affect both the mechanical properties and microstructure of the hydrogels. The added cellulose acts as a physical-cross-linking agent strengthening the hydrogen-bond network as well as a reinforcing phase improving the mechanical properties. However, chemical cross-linking of an unreinforced gel leads to unfavourable bonding and cellulose network formation, resulting in drastically increased pore sizes and reduced mechanical properties. In both cases, chemical cross-linking leads to larger internal pores.

Biomechanical properties of fishing lines of the glowworm Arachnocampa luminosa (Diptera; Keroplatidae).

Animals use adhesive secretions in highly diverse ways, such as for settlement, egg anchorage, mating, active or passive defence, etc. One of the most interesting functions is the use of bioadhesives to capture prey, as the bonding has to be performed within milliseconds and often under unfavourable conditions. While much is understood about the adhesive and biomechanical properties of the threads of other hunters such as spiders, barely anything is documented about those of the New Zealand glowworm Arachnocampa luminosa. We analysed tensile properties of the fishing lines of the New Zealand glowworm Arachnocampa luminosa under natural and dry conditions and measured their adhesion energy to different surfaces. The capture system of A. luminosa is highly adapted to the prevailing conditions (13-15 °C, relative humidity of 98%) whereby the wet fishing lines only show a bonding ability at high relative humidity (>80%) with a mean adhesive energy from 20-45 N/m and a stronger adhesion to polar surfaces. Wet threads show a slightly higher breaking strain value than dried threads, whereas the tensile strength of wet threads was much lower. The analyses show that breaking stress and strain values in Arachnocampa luminosa were very low in comparison to related Arachnocampa species and spider silk threads but exhibit much higher adhesion energy values. While the mechanical differences between the threads of various Arachnocampa species might be consequence of the different sampling and handling of the threads prior to the tests, differences to spiders could be explained by habitat differences and differences in the material ultrastructure. Orb web spiders produce viscid silk consisting of ß-pleated sheets, whereas Arachnocampa has cross-ß-sheet crystallites within its silk. As a functional explanation, the low tear strength for A. luminosa comprises a safety mechanism and ensures the entire nest is not pulled down by prey which is too heavy.

Direct 3D printing of monolithic ion exchange adsorbers.

Monolithic adsorbers with anion exchange (AEX) properties have been 3D printed in an easy one-step process, i.e. not requiring post-functionalization to introduce the AEX ligands. The adsorber, 3D printed using a commercial digital light processing (DLP) printer, was obtained by copolymerisation of a bifunctional monomer bearing a positively charged quaternary amine as well as an acrylate group, with the biocompatible crosslinker polyethylene glycol diacrylate (PEGDA). To increase the surface area, polyethylene glycol was introduced into the material formulation as pore forming agent. The influence of photoinitiator (Omnirad 819) and photoabsorber (Reactive Orange 16, RO16) concentration was investigated in order to optimize printing resolution, allowing to reliably 3D print features as small as 200 µm and of highly complex Schoen Gyroids. Protein binding was measured on AEX adsorbers with a range of ligand densities (0.00, 2.03, 2.60 and 3.18 mmol/mL) using bovine serum albumin (BSA) and c-phycocyanin (CPC) as model proteins. The highest equilibrium binding capacity was found for the material presenting the lowest ligand density analysed (2.03 mmol/mL), adsorbing 73.7 ± 5.9 mg/mL and 38.0 ± 2.2 mg/mL of BSA and CPC, respectively. This novel 3D printed material displayed binding capacities in par or even higher than commercially available chromatographic resins. We expect that the herein presented approach of using bifunctional monomers, bearing commonly used chromatography ligands, will help overcome the material limitations currently refraining 3D printing applications in separation sciences.

Modelling ordered packed beds of spheres: The importance of bed orientation and the influence of tortuosity on dispersion.

Ordered packing has previously been considered for porous media applications in the industrial and analytical worlds, with implementation constrained only by the lack of feasible fabrication methods. Additive manufacturing now provides the answer to this limitation, which leads to the novel domain of customized ordered packing and a variety of optimized geometries. In this work, the chromatographic behaviour of ordered configurations of particles was described using computational fluid dynamics methods based on the Lattice Boltzmann Model. The model was first validated by matching van Deemter trends for ordered and random packings shown in previous research. The influence of rotations of the ordered configurations was then considered, indicating that orientational changes with respect to the main flow axis can strongly affect minimum plate height. In particular, it is demonstrated that targeted rotations of ordered packings can reduce axial dispersion while improving transverse dispersion, thus improving chromatographic performance. This principle is clearly shown in a strong linear correlation between tortuosity and plate height, offering an additional parameter to enable a priori control of the performance of ordered packings. Furthermore, rotation of the packing does not change porosity or surface area and has a relatively small effect on permeability. Thus, highly permeable packings with poor dispersion can be improved in terms of chromatographic impedance by simple rotation of the packing orientation. This work further demonstrates the advantages of ordered packings over randomly packed beds, and introduces new perspectives on the development of chromatographic structures with improved performance.

Formation of supramolecular protein structures on gold surfaces.

Recent research has highlighted the exciting possibilities enabled by the use of protein structures as nanocomponents to form functional nanodevices. To this end, control over protein-protein and protein-surface interactions is essential. In this study, the authors probe the interaction of human peroxiredoxin 3 with gold surfaces, a protein that has been previously identified as having potential use in nanotechnology. Analytical ultracentrifugation and transmission electron microscopy revealed the pH mediated assembly of protein toroids into tubular structures across a small pH range. Quartz crystal microbalance with dissipation measurements showed differences in absorbed protein mass when pH is switched from pH 8.0 to 7.2, in line with the formation of supramolecular structures observed in solution studies. Scanning tunneling microscopy under ambient conditions showed that these protein tubes form on surfaces in a concentration dependent manner, with a tendency for protein adsorption and supramolecular assembly at the edges of Au(111) terraces. Finally, self-assembled monolayer modification of Au surfaces was explored as a means to control the adsorption and orientation of pH triggered protein structures.

Microscopic and infrared spectroscopic comparison of the underwater adhesives produced by germlings of the brown seaweed species Durvillaea antarctica and Hormosira banksii.

Adhesives from marine organisms are often the source of inspiration for the development of glues able to create durable bonds in wet environments. In this work, we investigated the adhesive secretions produced by germlings of two large seaweed species from the South Pacific, Durvillaea antarctica, also named 'the strongest kelp in the word', and its close relative Hormosira banksii The comparative analysis was based on optical and scanning electron microscopy imaging as well as Fourier transform infrared (FTIR) spectroscopy and principal component analysis (PCA). For both species, the egg surface presents peripheral vesicles which are released soon after fertilization to discharge a primary adhesive. This is characterized by peaks representative of carbohydrate molecules. A secondary protein-based adhesive is then secreted in the early developmental stages of the germlings. Energy dispersive X-ray, FTIR and PCA indicate that D. antarctica secretions also contain sulfated moieties, and become cross-linked with time, both conferring strong adhesive and cohesive properties. On the other hand, H. banksii secretions are complemented by the putative adhesive phlorotannins, and are characterized by a simple mechanism in which all constituents are released with the same rate and with no apparent cross-linking. It is also noted that the release of adhesive materials appears to be faster and more copious in D. antarctica than in H. banksii Overall, this study highlights that both quantity and quality of the adhesives matter in explaining the superior attachment ability of D. antarctica.

Experimental characterization of the transport phenomena, adsorption, and elution in a protein A affinity monolithic medium.

A commercially available convective interaction media (CIM) Protein A monolithic column was fully characterized in view of its application for the affinity capture of IgG in monoclonal antibody production processes. By means of moment analysis, the interstitial porosity and axial dispersion coefficient were determined. The frontal analysis method of characteristic points was employed, for the first time with monolithic media, to determine the dynamic binding capacity. The effects of the flow rate and pH on the total recovery of polyclonal IgG and elution profile were evaluated. A comparison with literature data for Protein A chromatography beads demonstrate the superior bed utilization of monolithic media, which gave better performance at lower residence times.

Adsorption of chemically synthesized mussel adhesive peptide sequences containing DOPA on stainless steel.

The adsorption of proteins at solid-liquid interfaces is important in biosensor and biomaterial applications. Marine mussels affix themselves to surfaces using a highly cross-linked, protein-based adhesive containing a high proportion of L-3,4-dihydroxyphenylalanine (DOPA) residues. In this work, the effect of DOPA residues on protein adhesion on stainless steel surfaces was studied using a quartz crystal microbalance with dissipation system. The adsorption of two repetitive peptide motifs, KGYKYYGGSS and KGYKYY, from the mussel Mytilus edulis foot protein 5 on stainless steel was studied before and after chemo-enzymatic modification of tyrosine residues to DOPA using mushroom tyrosinase. Conversion from tyrosine to DOPA, evaluated by HPLC, was in the range 70-99%. DOPA-modified sequences showed fourfold greater adhesion than unmodified M. edulis foot protein 5 motifs.

Experimental and computational analysis of a novel flow channel to assess the adhesion strength of sessile marine organisms.

Bioadhesives produced by marine macroalgae represent a potential source of inspiration for the development of water-resistant adhesives. Assessing their adhesion strength, however, remains difficult owing to low volumes of adhesive material produced, low solubility and rapid curing time. These difficulties can be circumvented by testing the adhesion strength of macroalgae propagules attached to a substrate. In this paper, we present a simple, novel flow channel used to test the adhesion strength of the germlings of the fucalean alga Hormosira banksii to four substrates of biomedical relevance (PMMA, agar, gelatin and gelatin + lipid). The adhesion strength of H. banksii germlings was found to increase in a time-dependent manner, with minimal adhesion success after a settlement period of 6 h and maximum adhesion strength achieved 24 h after initial settlement. Adhesion success increased most dramatically between 6 and 12 h settlement time, while no additional increase in adhesion strength was recorded for settlement times over 24 h. No significant difference in adhesion strength to the various substrates was observed. Computational fluid dynamics (CFD) was used to estimate the influence of fluid velocity and germling density on drag force acting on the settled organisms. CFD modelling showed that, on average, the drag force decreased with increasing germling number, suggesting that germlings would benefit from gregarious settlement behaviour. Collectively, our results contribute to a better understanding of the mechanisms allowing benthic marine organisms to thrive in hydrodynamically stressful environments and provide useful insights for further investigations.