Biotechnology Journal

PurposeExtracellular vesicles (EVs) are increasingly explored as natural vehicles for drug delivery and gene therapy approaches. However, reproducible yield and scalability of EV production still pose major challenges in the clinical translation of EV-based therapies. In this study, we sought to quantify and characterize EVs released by suspension-cultured HEK293 cells (Expi293F cells) grown in shaker flasks or small-scale bioreactors, to investigate how the culturing environment affects EV production yield. MethodsExpi293F cells were cultivated (N=3) in either shaker flasks or a bioreactor system, and total cell density, viability, and size were monitored. Supernatants were drawn daily post-cell seeding and were analyzed for EV quantity, size, morphology, and CD63 expression. ResultsNo significant differences were observed in terms of total cell density, viability, and cell size between both cultivation settings. However, cultivation of Expi293F cells in the bioreactor environment significantly increased EV yield by 3-fold compared to shaker flask cultivation (p < 0.01). Other parameters such as average nanoparticle size, EV morphology, and CD63 expression remained comparable between both cultivation methods. ConclusionThese results demonstrate that Expi293F-derived EV yield can be increased by culturing cells in a scalable bioreactor system. These findings pave the way towards the production of therapeutic-based EVs in a scalable and reproducible manner suitable for future (pre-)clinical applications.

mRNA therapeutics have demonstrated transformative potential in infectious disease, oncology and genetic disorders. Parallel to the rapid clinical advancement of mRNA therapies, research into in vitro transcription (IVT), the pivotal process of mRNA manufacturing, has intensified significantly. However, the majority of these studies omitted cap analog, an essential substrate for co-transcriptional capped IVT (co-IVT), likely to simplify experimental systems. Nevertheless, co-IVT remains the dominant industrial standard for the production of mRNA therapeutics. Here, we report an optimized co-IVT process that achieves a yield of more than 26 g/L while maintaining capping efficiency of over 99.5%, and achieving a 30-fold reduction in double-stranded RNA (dsRNA), the most critical process-related impurity. These performance gains substantially improve mRNA production efficiency and enhance mRNA quality, thereby accelerating the transition to commercial-scale manufacturing of mRNA therapeutics. Moreover, the performance was attained using either of two mechanistically distinct engineered T7 RNA polymerase (RNAP) mutants. Both mutants enabled robust mRNA synthesis under process conditions that have not been previously reported. These observations provide mechanistic insights into IVT and advance our fundamental understanding of this critical bio-manufacturing step.

Extracellular vesicles (EVs) are mediators of intercellular communication, yet their impact on Chinese Hamster Ovary (CHO) cell physiology and bioprocess performance remains poorly understood. Here, we investigated whether small EVs (sEVs) and large EVs (LgEVs) that accumulate during fed-batch and perfusion cultures modulate CHO cell growth, metabolism, apoptosis, and monoclonal antibody (mAb) production. EVs isolated from early- and late-stage cultures were added to fresh CHO cultures grown with or without glutamine supplementation. Only LgEVs had a significant impact. Late-stage LgEVs markedly altered CHO-cell behavior, reducing cell proliferation, increasing apoptosis under glutamine-limited conditions, and substantially enhancing mAb productivity in a dose-dependent manner. Glutamine supplementation largely alleviated the growth-inhibitory and pro-apoptotic effects of LgEVs while preserving their positive impact on productivity, suggesting that glutamine decouples EV-mediated stress from productivity enhancement. Metabolic analyses revealed increased glucose consumption, a glutamine-dependent shift between glycine and alanine overflow metabolism, and remodeling of amino-acid utilization. Metabolic flux analysis further demonstrated enhanced glycolytic overflow and increased reliance on amino acid-supported anaplerosis. Conversely, selective removal of LgEVs from perfusion medium significantly improved cell expansion without reducing antibody production, supporting an inhibitory role for late-stage LgEVs. These LgEVs were enriched in let-7 family miRNAs and miR-21, consistent with RNAseq analyses demonstrating stress-associated enrichment of these miRNAs in CHO EVs and with functional studies showing that let-7a and miR-21reduce CHO-cell growth. Together, these observations suggest that selective miRNA loading contributes to the growth, metabolic, and productivity phenotypes elicited by late-stage LgEVs. Our findings identify LgEVs as endogenous regulators of CHO-cell physiology and potential targets for optimizing high-density fed-batch and perfusion biomanufacturing processes. HighlightsO_LIEndogenous late-stage Large Extracellular Vesicles (LgEVs) reduce CHO cell growth but boost specific mAb productivity. C_LIO_LIGlutamine supplementation rescues LgEV-mediated growth inhibition and apoptosis. C_LIO_LIMetabolic Flux Analysis (MFA) based on the dynamic behavior of amino acid and other metabolite and substrate concentrations reveals the pyruvate node as a metabolic bottleneck and the associated lactate overflow metabolism as resulting from LgEV exposure. C_LIO_LIStress-associated let-7 and miR-21 microRNAs are highly enriched on a per-EV basis in late-stage LgEVs. C_LIO_LISelective removal of LgEVs improves perfusion cell growth without impacting antibody titer. C_LI

Automated platforms such as Chi.Bio enable simultaneous monitoring of optical density and fluorescent reporter expression in 20 ml reactor cultures with controllable pump systems. As such, they provide an appealing option for contemporary gene expression quantification, quantitative physiology, and laboratory evolution and ecology experiments. While optical density calibration for this device is well established, no equivalent calibration framework exists for fluorescence, making quantitative comparison with reference instruments unreliable. Here, we characterize Chi.Bio fluorescence capabilities using fluorescent calibration microspheres and fixed GFP-expressing S. cerevisiae and E. coli cells, compared with orthogonal plate-reader measurements. We show that microsphere fluorescence is detectable and scales linearly with concentration, whereas the GFP signal from both species falls below the device detection limit. Comparison of background-correction strategies indicates that direct subtraction of a non-fluorescent control measured within the same device yields more reliable fluorescence estimates than the commonly used on-line normalization method. Knowledge of these sensitivity boundaries of the device provides practical guidelines for experimental design of future studies.

The commercial production of cell-based food is currently hindered by existing bioreactor technologies, which require substantial capital investment, specialized operating skills, and complex processing setups. To democratize cell-based food production, we developed the "oxy-thru cultivator"--a simple, autoclavable, closed-bag bioreactor fabricated from polydimethylsiloxane (PDMS). By leveraging the high oxygen-permeability of PDMS, this platform enables passive oxygenation across the entire vessel wall, eliminating the need for external aeration or mechanical sparging. During testing, the cultivator maintained a stable culture environment over 23 days, showing no cytotoxic leachables and retaining both structural integrity and sterility across 10 autoclave cycles. This robustness supported the continuous cultivation of DF-1 cells for 74 days. Using a standardized subculture scheme, we successfully harvested an estimated 2.60 g of cell-based biomass per cultivator over five passages. Notably, the platform achieved a 127% monthly labor productivity compared to conventional bioreactors and was easily operated by researchers without specialized training. Additionally, the system successfully supported the expansion of both mammalian and primary avian cell lines. With a minimal equipment footprint that reduces CapEx, and a reusable silicone vessel that lowers OpEx, the oxy-thru cultivator offers a highly practical, accessible pathway toward scaling up cellular agriculture. Graphical Abstract O_FIG O_LINKSMALLFIG WIDTH=200 HEIGHT=104 SRC="FIGDIR/small/729703v1_ufig1.gif" ALT="Figure 1"> View larger version (27K): org.highwire.dtl.DTLVardef@bf2abforg.highwire.dtl.DTLVardef@8f9231org.highwire.dtl.DTLVardef@1c6fc63org.highwire.dtl.DTLVardef@e3e537_HPS_FORMAT_FIGEXP M_FIG C_FIG

O_LIThe effect of some bioactive compounds on living organisms is dependent on their concentration and gradients, as is the case of hormones and signalling peptides, determining cell identity, activity and organism development. C_LIO_LIThere are a handful of methods that allow to produce spatially confined peaks of concentration local application of biochemicals on plants, such as agar blocks and microinjection, but they lack in precision, throughput and/or simplicity. C_LIO_LIWe developed the MicroTron, a microfluidics-based method specifically for filamentous organisms or life cycle stages, like the moss plant Physcomitrium patens protonemata, that serves as a platform for the application of chemicals on single cells and study the cell response. C_LIO_LIWe show how chemical applications could be performed on cells, either on the side or apically with dyes and hormones, targeting the cell wall, cell membrane, cytosol and nucleus. C_LIO_LITreatments could be applied on single filaments and with a precision of up to single cells in optimal conditions. C_LIO_LIThis method could be used to study live responses to chemicals with high spatiotemporal resolution. C_LI

Methanogenic archaea, such as Methanothermobacter marburgensis, represent a powerful biological platform for carbon capture and valorization, directly converting carbon dioxide (CO2) and molecular hydrogen (H2) into proteinogenic amino acids (AAs). In this study, we present a controlled and scalable strategy for tailoring AA production (biosynthesis and secretion) in continuous gas fermentation. By applying various Design of Experiments (DOE) techniques, we systematically identified and optimized key process parameters governing AA biosynthesis and shaping a targeted AA secretion profile. A hybrid modeling framework combining experimental data with scale-independent parameters derived from computational fluid dynamics (CFD) enabled robust performance prediction across bioreactor scales. This model-driven approach successfully translated the process from 120 mL glass bottles via 2 L to 150 L reactors, corresponding to a reaction-volume scale-up factor of 2000. These findings set the foundation for a robust and predictive platform for sustainable AA production, positioning archaea as a high-potential alternative in industrial biotechnology.

The suspension culture of pluripotent stem (PS) cells in stirred bioreactors poses a delicate balance between maintaining homogeneous cell dispersion and avoiding excessive shear stress that can compromise cell viability and pluripotency. In this study, we used computational fluid dynamics (CFD) coupled with a discrete particle method (DPM) to simulate iPS cell behavior in a 5 mL delta-impeller stirred tank. Our analysis revealed that upward flow at the tank bottom and downward flow at the top are critical for maintaining a stable suspension. To optimize the stirring protocol, we applied Bayesian optimization to identify a time-dependent stirring schedule that begins with a high-speed phase for resuspension, followed by a low-speed phase for sustained suspension with minimal hydrodynamic stress. The optimized schedule demonstrated improved suspension ratio and reduced slip velocity, indicating lower mechanical stress on cells. These findings provide engineering insights into scalable bioreactor operation, contributing to the design of robust iPS cell manufacturing systems.

BackgroundRecombinant expression of the SARS-CoV-2 receptor-binding domain (RBD) is essential for vaccine development, serological diagnostics, and mechanistic studies. Primary human fibroblasts offer physiologically relevant protein folding and post-translational modification, yet their short lifespan limits scalable production. We used an immortalized human splenic fibroblast cell line to stably express RBD-sfGFP for longitudinal characterization and downstream studies. MethodsImmortalized human primary splenic fibroblasts were transfected by electroporation with a plasmid encoding SARS-CoV-2 RBD fused to superfolder GFP (sfGFP), with a neomycin resistance cassette (neoR) for G418 selection. Four independent G418-resistant cultures (n=4), designated HPSF-IM-RBD-BHSKPU T1-T4, were established from distinct selection flasks. Based on previous screenings, two cultures (T1, T3) were monitored for 98 days (14 passages, P1-P14); two cultures (T2, T4) were monitored for 42 days (6 passages, P1-P6). RBD-sfGFP expression was assessed by fluorescence microscopy at 7-day intervals. For each timepoint, 2 fields were imaged and analyzed for relative fluorescence intensity (normalized to global maximum = 100%) and mean fluorescence intensity (MFI, normalized to global maximum = 100%). Coefficient of variation (CV), linear regression, and Pearson correlation were calculated. ResultsAll four cultures exhibited robust GFP fluorescence, confirming stable transgene retention. Expression ranking: T1 (93.1% +/- 3.6%) > T3 (89.2% +/- 3.4%) > T2 (84.2% +/- 3.2%) > T4 (79.7% +/- 3.9%). Long-term cultures T1 and T3 retained [~]100% of Day 7 signal at Day 98 (T1: 100.7%; T3: 100.0%). Expression exhibited passage-dependent oscillation rather than progressive silencing. CV increased over time in T1 (1.5% -> 8.5%), indicating growing inter-cellular heterogeneity. A strong positive correlation between fluorescence and MFI (Pearson r = 0.823, p = 7.44 x 10-11) suggested coherent population-level regulation. ConclusionsHPSF-IM-RBD-BHSKPU cells stably retain RBD-sfGFP expression for over 3 months, validating their utility as a recombinant protein production platform. However, oscillatory dynamics and increasing heterogeneity are consistent with position-effect variegation at distinct integration loci. Consequently, early passages (P1-P4) are optimal for applications requiring maximal uniformity. Ultimately, these cells provide a practical tool for RBD production and a valuable model for studying epigenetic regulation of transgene expression in human primary fibroblast backgrounds.

Multi-stage continuous bioprocessing can increase volumetric productivity, operational consistency, and process throughput, but its design is complicated by coupling among dilution rate, reactor volume, feed allocation, and cellular physiology. Here, we present ContiDesigner, available at https://chemnettools.anc.univie.ac.at/ContiDesigner/, a mechanistic steady-state framework and interactive web tool for the system-level design of continuous fermentation cascades. Comparing one- and two-stage configurations at equal total reactor volume and outlet flow, ContiDesigner reveals how internal flow and reactor volume allocation shape space-time yield and identifies productivity-maximizing operating conditions. Compared with one-stage processes, two-stage cascades favor lower over-all dilution rates, thereby preserving residence time in the production stage. The first-stage dilution rate approaches the corresponding one-stage productivity optimum, but the cascade optimum occurs earlier, reflecting a system-level compromise between biomass generation and production-stage residence time. However, two-stage operation outperforms optimized one-stage operation only when non-growth-associated production in the second stage is sufficiently strong, whereas increasing growth coupling favors one-stage operation. Two case studies demonstrate both the potential and limits of process intensification. An optimized two-stage design is predicted to achieve a more than 1.5 fold increase in space-time yield for poly-R-3-hydroxybutyrate (PHB) production compared with a published experimental five-stage cascade, whereas the lactic acid case study identifies conditions under which staging offers no advantage. ContiDesigner translates these design principles into an accessible workflow to explore feasible operating regions and prioritize cascade designs for experimental evaluation. Graphical Abstract O_FIG O_LINKSMALLFIG WIDTH=200 HEIGHT=130 SRC="FIGDIR/small/743657v1_ufig1.gif" ALT="Figure 1"> View larger version (37K): org.highwire.dtl.DTLVardef@ef58faorg.highwire.dtl.DTLVardef@1ba88a4org.highwire.dtl.DTLVardef@160edd3org.highwire.dtl.DTLVardef@9dda34_HPS_FORMAT_FIGEXP M_FIG C_FIG O_LIContiDesigner enables system-level design of continuous fermentation cascades C_LIO_LIHigh stage-one dilution supports biomass generation C_LIO_LILow stage-two dilution preserves productive residence time C_LIO_LIYet two-stage cascades favor lower overall dilution than one-stage systems C_LIO_LITwo-stage advantage requires strong non-growth-associated production in stage two C_LI

The development of cost-effective, serum-free media is critical for scalable cultivated meat production. This study used high-throughput screening through a Design of Experiments (DoE) approach to develop an animal-free, serum-free medium (MMM1) specifically for the C2C12 murine myoblasts model cell line with applicability in cultivated meat research including for pet food. Low cost, food-grade inputs such as methylcellulose and spirulina extract resulted in significant cell growth improvements. The optimised MMM1 formulation containing low cost, food-grade inputs, achieved cumulative population doublings comparable to 10% (v/v) fetal bovine serum over four consecutive passages. Furthermore, MMM1 supported scalable cell expansion on commercially available dextran-based microcarriers (Cytodex-3) in both static and agitated conditions in spinner flasks, matching growth rates of serum-based controls. Finally, transitioning to a food-grade DMEM/F12 basal medium maintained cell proliferation equivalent to the pharmaceutical-grade DMEM/F12, but at a significantly lower cost, thus offering a viable strategy to substantially reduce biomanufacturing costs which is a critical challenge in cultivated meat production.

Given the current global environmental challenges, waste biomass is an attractive renewable resource for circular economies. Gasification of biomass yields syngas (CO, CO2, and H2) that is a suitable feedstock for gas fermentation in biomanufacturing of fuels and chemicals using acetogen microbes. While it is generally known that syngas composition influences both acetogen growth and process performance, we are lacking a consistent dataset quantifying these effects under controlled fermentation conditions. Here, we mapped the metabolic response of the model-acetogen Clostridium autoethanogenum to seven synthetic syngas mixtures during exponential batch growth in bioreactor fermentations. Notably, distinct gas compositions resulted in different fermentation profiles, affecting both growth and metabolite production. Maximum specific growth rates ranged within 0.05 0.13 h-1, with slower growth for low-CO mixtures. While acetate and ethanol production yields varied between 20-133 and 76-353 mmol per gram dry cell weight, respectively, minor production of 2,3-butanediol was detected. All syngas mixtures supported co-utilization of CO and H2, though gas uptake stoichiometry only moderately correlated with syngas content. Importantly, gas uptake stoichiometry strongly influenced carbon partitioning, with higher relative H2 uptake reducing CO2 loss or even realizing CO2 fixation together with increasing carbon flow towards metabolites. Interestingly, higher syngas H2 content favored ethanol and 2,3-butanediol production, while higher H2:CO uptake ratios increased total flux through the Wood-Ljungdahl pathway rather than selectively favoring reduced by-products. Our results are valuable for a better understanding of syngas composition effects on the acetogen biocatalyst and for process engineering towards optimizing gas fermentation performance. HighlightsO_LISyngas composition affects acetogen growth, gas uptake, and carbon distribution C_LIO_LIHigher H2:CO uptake ratios increase carbon flow through the Wood-Ljungdahl pathway C_LIO_LIHigher relative H2 uptake reduces CO2 loss and increases metabolite production C_LI

Messenger RNA (mRNA)-based therapeutics have emerged as a new class of biological medicines, clearly exemplified by the global deployment of mRNA vaccines against the COVID-19 pandemic. Currently, therapeutic mRNA is primarily produced through in vitro transcription that suffers high production costs. Until now, intracellular manufacture of mRNA has been challenging due to the presence of ubiquitous RNases in vivo. Here, we have developed a new approach that protects eukaryotic mRNA from RNase degradation ensuring longevity and integrity of mRNA inside microbial cells. Through targeted strain and molecular engineering, our approach involves specially designed inserts in mRNA that facilitate formation of stabilized and protected protein-mRNA complexes. In addition to vastly improved stability, the protein-mRNA complexes enable convenient purification of mRNA from cell lysate with high purity using conventional chromatography. The work reported here promises a scalable, rapid, and low-cost approach to produce fully functional eukaryotic mRNA using well-known microbial systems.

Efficient and heritable genome editing in plants remains constrained by transformation bottlenecks and reliance on tissue culture-based regeneration. Targeting the male germline offers a promising alternative for DNA-free genome modification. Here, we report a polymeric nanoparticle platform for the delivery of RNA-based CRISPR/Cas9 components into Arabidopsis thaliana pollen, establishing a foundation for sperm transfection-assisted genome editing (STAGE)-like approaches in plants. Poly(2-dimethylaminoethyl methacrylate) (PDMAEMA)-based polyplexes were designed to independently encapsulate Cas9 mRNA and ATTO 550-labeled guide RNA, forming nanoparticles with hydrodynamic diameters of [~]146 nm and condensed cores of 20-30 nm. Following internalization and cytosolic release, Cas9 mRNA translation enabled the nuclear localization of ATTO 550-labeled gRNA, as confirmed by confocal imaging and fluorescence lifetime (TauSense) analysis. Fluorescent signals corresponding to the CRISPR RNPs were detected in both vegetative and sperm cell nuclei, with higher accumulation in the vegetative nucleus. Together, these results demonstrate the feasibility of RNA-mediated delivery and intracellular assembly of CRISPR/Cas9 RNPs in plant male gametophytes. By bypassing tissue culture and DNA integration, this nanoparticle-based approach establishes a framework for a more efficient mechanism for introducing heritable genome modifications in plants. Graphical Abstract O_FIG O_LINKSMALLFIG WIDTH=200 HEIGHT=91 SRC="FIGDIR/small/733037v1_ufig1.gif" ALT="Figure 1"> View larger version (51K): org.highwire.dtl.DTLVardef@170f7a5org.highwire.dtl.DTLVardef@1929c6forg.highwire.dtl.DTLVardef@5c4a94org.highwire.dtl.DTLVardef@1243cc8_HPS_FORMAT_FIGEXP M_FIG C_FIG

BackgroundContinuous glucose monitoring (CGM) systems are used not only for retrospective assessment of the glycemic profile but also for real-time decision-making, including automated insulin delivery. Accordingly, CGM performance characterization must capture not only the agreement of individual paired values but also the systems ability to reproduce the direction, rate, amplitude, and shape of glucose concentration change. Summary metrics, most notably MARD, cannot establish whether an observed deviation reflects an error in the formation of the test profile itself, a constant sensor offset, amplitude compression, a change in response rate, temporal misalignment, or hysteresis. ObjectiveTo adapt a programmable flow-based in vitro platform for the separate assessment of the experimentally delivered glucose profile and the dynamic response of CGM systems, and to propose a set of metrics that decomposes dynamic error into its components. MethodsGLU profiles were generated by programmable mixing of solutions at a constant total flow rate of 2 mL/min. Actual GLU concentration was independently measured with a SUPER GL2 glucose analyzer. Four static levels, three repeats of a 5.5[-&gt;]12.0[-&gt;]5.5 mmol/L profile, three repeats of a 6.0[-&gt;]3.0[-&gt;]6.0 mmol/L hypoglycemic profile, three 5.0[-&gt;]15.0[-&gt;]5.0 mmol/L profiles at different rates, one complex 4[-&gt;]18[-&gt;]3[-&gt;]12[-&gt;]5.5 mmol/L profile, and two proof-of-concept sensor experiments at 100- and 200-min transitions were investigated. Dynamic response was characterized by bias, MAE, RMSE, MARD, amplitude transfer coefficient K_A, rate transfer coefficients K_up and K_down, normalized shape RMSE, residual shift, and hysteresis loop area. ResultsAt the static levels, measured GLU exceeded the programmed value by 0.234-0.780 mmol/L. In the repeated 5.5[-&gt;]12.0[-&gt;]5.5 profiles, the ratio of actual to programmed rate was 0.978-1.083 on the rising phase and 0.987-1.157 on the falling phase, while the amplitude transfer coefficient was 0.967-1.066. In the hypoglycemic profile, minimum GLU was 2.55- 2.96 mmol/L, and time below 3.0 mmol/L was 15.2-72.6 min. The measured rates of 0.0519, 0.1045, and 0.2027 mmol/L/min preserved the intended ratio of approximately 1:2:4. In the complex profile, the programmed plateau of 18 mmol/L was not reached: mean measured GLU was 16.20 mmol/L. For CGM-A, K_A was 0.682 and 0.650, and K_up/K_down were 0.666/0.730 and 0.634/0.626; the corresponding values for CGM-B were 1.228 and 1.128, and 1.564/1.328 and 1.276/1.145. Hysteresis loop area differed 5- to 10-fold between the two sensor responses, exceeding an order of magnitude at the 100-min transition. ConclusionThe programmed concentration should be treated as a control setpoint, rather than as a reference measurement. The "programmed trajectory -- measured glucose -- CGM output" cascade first allows quantitative assessment of the agreement between the programmed and actually realized profile and only then separate characterization of sensor response. Decomposition of dynamic error into amplitude, rate, shape, and hysteresis components reveals differences that a single MARD value or correlation coefficient cannot capture.

Bacterial microcompartments (MCPs) are versatile proteinaceous organelles that compartmentalize metabolic pathways, offering promising scaffolds for synthetic biology and metabolic engineering. However, designing customized nanobioreactors requires distinguishing structurally indispensable shell proteins from those that can be modified or deleted to tune shell permeability without disrupting core organelle assembly. In this study, we performed a systematic biophysical and metabolic characterization of the hexameric shell protein PduU to evaluate its potential as a modular platform for synthetic organelle engineering. We tested whether deleting pduU or selectively truncating its N-terminal {beta}-barrel domain preserves shell assembly, metabolite flux, and intermediate confinement. Our results demonstrate that PduU modifications alter shell permeability while fully maintaining organelle structural integrity, monodispersity, and electrostatic colloidal stability. Crucially, this modulation in permeability redirects internal metabolic flux toward the energy-generating propionate pathway, resulting in elevated cell biomass and significantly increased yields of propionate, an economically vital industrial platform chemical. By establishing that PduU is a non-essential structural component whose modification tunes small-molecule flux, this work highlights PduU as a flexible locus for shell engineering, providing a scalable strategy for biomanufacturing of high-value bio-based products in tailor-made MCP nanobioreactors.

Microbial fuel cells (MFCs) have been widely investigated as decentralized bioelectrochemical systems capable of converting organic substrates into electricity. However, their long-term autonomous operation is constrained by substrate depletion in the anode compartment, leading to metabolic starvation of electroactive biofilms and a decline in power output. Conventional MFC design treats substrate crossover through the membrane separator as a parasitic loss that reduces coulombic efficiency. In this work, we propose a conceptual inversion of this paradigm by considering controlled cathodic-to-anodic substrate crossover as a passive mechanism to sustain basal microbial metabolism during periods of substrate scarcity. A transport-reaction framework is developed to quantify the balance between membrane-mediated substrate flux and microbial maintenance demand within the anode biofilm. Based on this balance, a dimensionless maintenance crossover Damkohler number (Dam) is introduced to define three operational regimes: starvation-dominated (Dam >> 1), balanced autonomous (Dam {approx} 1), and crossover-dominated (Dam << 1). The framework integrates membrane transport theory with biofilm kinetics to evaluate the effects of separator properties, substrate gradients, and current-dependent electro-osmotic transport on system stability. Order-of-magnitude analysis indicates that achievable crossover fluxes span several orders of magnitude depending on separator characteristics, suggesting that membrane properties critically influence system behavior. This perspective reframes substrate crossover from a loss mechanism to a potential design variable, offering a conceptual tool for enhancing resilience and guiding separator selection in MFCs intended for long-duration, and low-maintenance operation. HighlightsO_LIControlled crossover can sustain microbial metabolism in MFCs C_LIO_LIIntroduces maintenance crossover Damkohler number (Dam) C_LIO_LIIdentifies regimes for autonomous and starvation operation C_LIO_LILinks membrane properties to long-term system stability C_LIO_LIReframes crossover as a design variable, not only a loss C_LI

Three-dimensional (3D) cell culture models, particularly multicellular tumor spheroids, have become essential tools for studying cancer biology, drug screening, and preclinical testing due to their ability to mimic physiological tumor microenvironments. However, traditional invasion assays, such as Boyden-chamber- or Transwell-based systems, often suffer from variability introduced by spheroid handling and transfer, compromising data reproducibility. Here, we present a novel, 3D-printed migration and invasion platform --the MQm-sert-- designed to standardize and streamline spheroid-based invasion assays while maintaining spheroid integrity. Fabricated via fused filament fabrication using biobased polylactic acid, the MQm-sert integrates a hanging-drop spheroid culture system (MQm-sert) with a membrane-based invasion chamber (M-sert), eliminating the need for disruptive spheroid transfer steps. Using synthetic tumor environment mimics (STEMs) composed of breast cancer cells (MDA-MB-231 and MCF7), mesenchymal stromal cells (MSCs), and human pulmonary microvascular endothelial cells (HPMECs), we quantified invasion dynamics and cellular interactions. This innovation significantly reduces experimental variability, as demonstrated by lower variance in invasive cell mass dimensions and cell density compared to conventional workflows. Beyond biological insights, the platform aligns with sustainability goals by leveraging cost-effective, open-source 3D printing, reducing reliance on commercial labware, and addressing key challenges in 3D cell culture standardization.

Extracellular vesicles (EVs) are nanoscale, cell-secreted mediators of intercellular communication with growing promise as therapeutic agents. Manufacturing practices, including EV isolation and storage approaches, are critical determinants of product consistency, purity, and potency. In this study, neural stem cell (NSC)-derived EVs were isolated from conditioned NSC culture media via oscillator-based isolation (OSC), ultracentrifugation (1 or 2 hours), and ultrafiltration, and were stored lyophilized or cryopreserved. Nanoparticle yield, size distribution, and subpopulation composition were evaluated by nano-flow cytometry, quantifying total nanoparticles, membrane-bound EVs and CD63+ EVs. Purification was calculated via particle-to-protein ratios, morphology was evaluated by transmission electron microscopy, and potency was assessed using a microglia morphology assay. Particle yield was comparable across isolation methods, though protein clearance varied, with OSC demonstrating purification relative to conditioned media. Lyophilized samples retained structural integrity, size, and population profiles comparable to cryopreserved samples. Lyophilized and cryopreserved EVs exhibited dose-dependent immunomodulatory activity in our microglia morphology assay, with significant effects observed at 200,000 EVs per cell. These findings highlight the importance of isolation method in EV product quality and support lyophilization as a viable storage strategy which overcomes the logistical limitations of cryopreservation, thereby advancing the development of a robust pipeline for therapeutic EV manufacture.

Lacticaseibacillus rhamnosus GG (LGG) is an important gut commensal bacterial strain that has been extensively studied in both industrial and health settings. Despite its long history of study, a high-quality genome-scale metabolic network model (GEM) for LGG has yet to be reconstructed. Only automatically-generated draft models have been published, which have notoriously limited functional accuracy. Furthermore, comprehensive nutrient requirements have not been established for well-controlled in vitro study. Here we present the first curated GEM for LGG using a new approach for reconstruction and validation that leverages multiple automatically-generated draft models, applied study literature, and high-throughput defined media experiments. In addition, our results include a series of chemically defined media, extensive single-component nutrient dropout growth data, insights from in silico and in vitro experiments into major secretion products lactate and indole-3-carboxaldehyde, a minimal medium and in silico characterization of LGGs nutrient requirements. Our approach for developing interdisciplinary research tools for LGG metabolism comprises a new framework that could be applied to many understudied microorganisms, particularly useful in studying bacteria within the human microbiome.