Engineering Commons^™

The Development Of Bioresorbable Fe-Mn Alloys For Orthopedic Implantation, Lia Stanciu

Composites at Lake Louise (CALL 2015)

Bioresorbable metals have immense potential to be used in the clinical treatment of a variety of soft and hard tissue injuries and disease. For many applications, the presence of a permanent device may cause severe negative effects and require re-intervention in the long-term. A transient support for a healing tissue is an attractive solution for orthopaedic and vascular interventions alike. For applications in bone fracture in particular, the human body requires fixation devices to support bone regrowth in the proper alignment, but only for a short period of time (typically 6-12 months). We aim to design bioresorbable materials to fill …

Additive Manufacturing Of Metals At High Rate Yielding Controlled Microstructure, James Mcguffin

Composites at Lake Louise (CALL 2015)

Additive manufacturing, AM, of metals can be accomplished by sequentially melting and solidifying a feedstock to create a freeform shape. In terms of commercial machines the most common feedstocks are flowable metal powders. However, wire feedstock offers advantages in many situations. Many are derived from connection to a large established industrial base (welding) and include a range of available compositions (including cored wire), high material utilization, and relative economy. While AM by localized fusion offers geometrical flexibility, but at a cost and with property compromises associated with the lack of familiar metallurgical processing tools such as mechanical working. Energy efficiency …

Final Program, Kathy Chan

Composites at Lake Louise (CALL 2015)

No abstract provided.

3d Printing Of Composites With Controlled Architecture, Brett Compton

Composites at Lake Louise (CALL 2015)

Additive manufacturing (AM) methods have greatly increased our ability to fabricate complex shapes and multi-material, hybrid architectures. However, better materials are needed which compete with conventional engineering materials and fully leverage the unique capabilities of 3D printing. Specifically, lightweight 3D-printable polymer composite materials are of considerable interest, as are new composites which incorporate hierarchical design aspects observed in natural materials, for example, bone, nacre, and wood.

This talk will focus on recent efforts in the development and characterization of epoxy-based 3D-printable composites for use with direct-write additive manufacturing. In this process, visco-elastic inks are deposited via extrusion through small nozzles …

Bicontinuous Networks Of Metal And Elastomer For Shape Morphing Composites, Robert Sheperd

Composites at Lake Louise (CALL 2015)

A composite of two entangled foams—silicone and a low melting temperature eutectic metal alloy will be presented. At room temperature, the material is stiff and thin sections (~1cm) can handle loads in bending excess of 0.5 kg. Above 60^oC, the melting temperature of the metal (T_m), the composite is rubbery and can undergo large deformation according to the properties of the elastomer foam. We have demonstrated this change in mechanical properties using standard mechanical testing techniques. Exploiting the dramatic tunability in stiffness, we have demonstrated that this material can: 1) vary in stiffness dramatically 1) take …

Additive Manufacturing Of Cellular Materials With Tailored Properties, Eric Duoss, Todd Weisgraber, Christopher Spadaccini, Thomas Wilson

Composites at Lake Louise (CALL 2015)

The ability to pattern complex materials with high-speed and low-cost three-dimensional (3D) printing techniques is highly desirable. Here, we present progress on developing siloxane-based feedstock formulations, known as “inks,” for a unique 3D printing approach called Direct Ink Writing (DIW). DIW is a low-cost, mask-less printing route that enables rapid design and patterning of planar and three-dimensional (3D) microstructures. In this filamentary printing approach, a concentrated ink with tailored viscoelastic properties is deposited through a micro-nozzle that is translated using a multi-axis positioning stage. The ink rapidly solidifies as it is extruded so that 3D structures with fine features may …

High Efficient Material And Process Combination For Future Aircraft Applications Based On Advanced Sheet Molding Compound Technologies, Marc Fette

Composites at Lake Louise (CALL 2015)

The increasing need for efficient passenger aircraft led to the development of innovative lightweight designs and an increasing demand on new lightweight materials such as carbon fiber reinforced plastics (CFRP) in the recent decades. Due to the high weight specific mechanical properties and the relatively high cost of raw materials, semi-finished and manufacturing the use of CFRP is limited on high performance applications, especially for components of the primary structures of aircraft.

Subsequently, fiber reinforced plastics (FRP) are also used in cabin and interior. Due to lower mechanical loads, but high requirements on fire protection, optics, surface and acoustics sandwich …

Supramolecular Peptide Composite Assemblies: Mimicking Biological Form And Function In Synthetic Systems, Erik Spoerke, Brad Jones, Jill Wheeler, Alina Martinez, Christina Ting, Mark Stevens

Composites at Lake Louise (CALL 2015)

Microtubules (MTs) are dynamic, multifunctional biomaterials that facilitate a range of complex biological process in cells ranging from regulation of cell morphology to separation of chromosomes during cell division to directing the intracellular transport of molecular cargo.¹ The remarkable precision, versatility, and dynamic nature of these non-equilibrium structures has motivated our desire to mimic their structure and function in synthetic materials. Here, I will identify a number of the key attributes responsible for MT form and function, and describe our efforts to merge computation and experiment to design, synthesize, and study a family of self-assembling peptides intended to mimic …

Towards Accelerated Medical Innovation, Jeff Karp

Composites at Lake Louise (CALL 2015)

This talk will explore platform technologies that are currently being developed in the KarpLab at the Brigham and Women’s Hospital, Harvard Medical School, to tackle medical problems. Namely, minimally invasive sealing of tissues and wounds including blood vessels and heart tissue, achieving long term local immunosuppression for treatment of vascularized composite allografts, and engineered stem cell therapy for treatment of diseases such as multiple sclerosis and prostate cancer. Many of the technologies developed in the Karplab harness lessons from nature for inspiration, as evolution represents millions and millions of years of research and development and thus nature truly is the …

Leveraging Large Data Sets In Continuous Chromatography Applications: Monitoring Critical Process Parameters Using Mvda, Engin Ayturk

Integrated Continuous Biomanufacturing II

Continuous multicolumn chromatography is gaining momentum in the industry as an enabling technology to establish continuous biomanufacturing platforms for monoclonal antibodies and recombinant proteins. Some companies are exploring continuous multicolumn chromatography processes as a stand-alone unit operation to improve specific productivity and/or reduce buffer consumption, while other companies are considering an integrated continuous downstream process based on continuous multicolumn chromatography.

One of the key features of continuous multicolumn chromatography is the amount of data generated during a single manufacturing batch or campaign. Traditional chromatography processes typically yield one (or a few) elution peaks per batch. Continuous chromatography processes, on the …

Cder's Emerging Technology Team, Kurt Brorson, Sau Lee

Integrated Continuous Biomanufacturing II

The newly formed Emerging Technology Team (ETT) draws membership from all CDER quality review, research and inspection functions, including Office of Biotechnology Products. The goal of the ETT is provide a primary point of contact for external inquiries regarding emerging technology in pharmaceutical and biotechnology manufacturing and quality control. The ETT will partner with review offices in a cross-functional manner and identify regulatory strategy and resolve roadblocks to new technologies relating to existing guidance, policy or practices related to review or inspection. The ETT’s initial focus will be innovation on novel products, manufacturing processes, or testing technologies or processes to …

Monitoring And Control Of Reproducibility In Quasi-Continuous Integrated Production Processes Of Active Pharmaceutical Ingredients, Reiner Luttman, Sven Oliver Borchert, Jan Patrick Voss, Gesine Cornelissen

Integrated Continuous Biomanufacturing II

The development of integrated production processes include the combination and transformation of current batch oriented unit operations into linked sequential/parallel production strategies.

The presented process starts with a two-stage upstream consisting of cell cultivation and subsequent protein production, which in turn results in a five step downstream process, consisting of cell clarification via a separator, retention of cellular debris using microfiltration, concentration of the secreted product by ultrafiltration with subsequent buffer exchange through diafiltration, followed by a final purification using column chromatography.

The three main operations cell breeding, protein production and the complete downstream line are running in series, but …

Exploring Continuous And Integrated Strategies For The Up- And Downstream Processing Of Human Mesenchymal Stem Cells, Barbara Cunha, Tiago Aguiar, Ricardo Silva, Cristina Peixoto, Manuel Carrondo, Margarida Serra, Paula Alves

Integrated Continuous Biomanufacturing II

The integration of up- and downstream unit operations can result in the elimination of hold steps, thus decreasing the footprint, and ultimately can create robust closed system operations. This type of design is desirable for the bioprocess of human mesenchymal stem cells (hMSC), where high numbers of pure cells, at low volumes, need to be delivered for therapy applications. The aim of this work is to perform a proof of concept of the integration of a continuous perfusion culture in bioreactors with a tangential flow filtration (TFF) system for the concentration and washing of hMSC. In particular, we have evaluated …

Pat Concepts For Chromatography: Real-Time Monitoring, Real-Time Control, And Cause Of Error Diagnostics, Nina Brestrich, Tobias Hahn, Adrian Sanden, Till Briskot, Jurgen Hubbuch

Integrated Continuous Biomanufacturing II

In the recent years, the growing competition in the biopharmaceutical industry due to biosimilars combined with market fluctuations and increasing product pipelines have given rise to the evaluation of continuous processing. Advantages include smaller equipment that may be disposable, an overall process intensification as well as steady-state operation. As variability should be managed by the continuous process itself to insure a consistent product quality, the development of advanced Process Analytical Technology (PAT) concepts is one crucial aspect for the implementation of continuous processing.

In chromatographic protein purification, process variability can lead to variations in retention volumes or peak shapes of …

Quality Systems For Continuous Manufacturing, Ron Branning

Integrated Continuous Biomanufacturing II

Continuous manufacturing is a familiar concept in large volume commercial commodity operations such as glass and plastic production. In the wake of the Tylenol cyanide poison scare in the 1970’s, pharmaceutical production at the J&J subsidiary McNeil converted to virtually closed, continuous manufacturing. Several Biotech firms tried to develop fermentation unit operations in the 1990’s that were based on the continuous manufacturing concept. Today there are a number of initiatives to update and realize the concept from bench top, such as MIT and Novartis’ sponsorship of start up firm Continuus’ production of solid dosage forms in Boston, to biodefense tractor-trailer …

Dynamic Oncolytic Measles Virus Production, Tanja Grein, Denise Salzig, Michael Muehlebach, Peter Czermak

Integrated Continuous Biomanufacturing II

Oncolytic viruses can be effective weapons against cancer with few treatment options. For example the tissue culture–adapted Edmonston strains of measles virus (MV) have altered its receptor specificity and became selectively oncolytic with attenuated pathogenicity. Russel et al. showed in 2014 full remission in an advanced stage multiple myeloma patient after systemic application of genetically modified MV. In this clinical trial, the patient was treated by intravenous infusion of 10¹¹ TCID₅₀ (50% tissue culture infectious dose) - of an engineered MV encoding human sodium iodide symporter. Appropriate medical treatment with oncolytic viruses calls for high concentrations and absolute …

Transforming The Present Into The Future With Uncertainty And Imprecision, Chales Cooney

Integrated Continuous Biomanufacturing II

No abstract provided.

How Continuous-Like Processes Improve Affordability For Viral Vaccines - Example Of Laiv, Jose Castillo

Integrated Continuous Biomanufacturing II

Designing a continuous process for a life viral vaccine could be seen useless, and challenging, as the virus infection will kill the cell substrate after 2-5 days of infection.

From the technical perspective, chaining the operations of cell culture under perfusion and viral production, clarification and capture / concentration is an efficient option to setup a small scale continuous automated process to manufacture massive amounts of viral vaccines.

We will show how beneficial it can be in terms of process development, manufacturing simplicity, capital expenditure and cost of production. Also, we will show how this approach can help producers of …

Advanced Computational Tools To Enhance Continuous Monoclonal Antibody Production, Maria M. Papathanasiou, Ana Quiroga, Athanasios Mantalaris, Efstratios Pistikopoulos

Integrated Continuous Biomanufacturing II

Leading pharmaceutical companies invest high percentage of their revenue in the improvement of existing technologies used for the production of monoclonal antibodies (mAbs). Recently, there has been a paradigm shift towards the development of continuous/quasi-continuous purification operations, aiming to reduce capital and operational costs [1]. At the moment, however, there are no standardized methods and/or tools that can be used for global control and monitoring of integrated processes.

Mathematical models and advanced computational tools can be the key for the development of robust, integrated processes, as they can provide valuable insight in the process dynamics and ensure optimal operation [2]. …

Protein Refinery Operations Lab (Pro Lab): A Sandbox For Continuous Protein Production & Advanced Process Control, Mark Brower, David Pollard, Finn Hung

Integrated Continuous Biomanufacturing II

Significant strides towards implementation of continuous bioprocessing are being made at an ever increasing rate. Advances in technology for traditional unit operations such as cell-retention devices in perfusion cell culture, continuous multi-column chromatography (CMCC) and single-pass tangential flow filtration have led to demonstrations of both semi-continuous and fully-continuous protein production processes operating at periodic steady states at the pilot-scale. Previous proof of concept work at Merck & Co., Inc. has shown an automated (DeltaV) and single-use monoclonal antibody (mAb) purification scheme through Protein A CMCC and pH viral inactivation with minimal human interaction for 30 days fed from a perfusion …

A Regulatory Perspective On Continuous Perfusion Production Of Rfviii, Robert Kozak

Integrated Continuous Biomanufacturing II

Continuous perfusion production has enabled flexible manufacturing of rFVIII, a large complex Biotech Product, for over two decades. Continuous improvement has driven frequent process, equipment and facility changes successfully performed utilizing comparability exercises.

Challenges in evaluating changes made to a continuous perfusion process includes assessment of impact to quality product attributes throughout the entire fermentation campaign which can be months in duration. Examples of process changes requiring more studies, those successfully supported by small scale development runs and API commercial characterization and an example resulting in non-implementation will be reviewed. Impact of changing Regulatory Environment on submission package requests will …

Small-Scale Platform For Rapid On-Demand Manufacturing Of Recombinant Proteins, J. Christopher Love

Integrated Continuous Biomanufacturing II

The current timeline for manufacturing high-quality recombinant proteins used for therapeutics and vaccines, and delivering them to patients, typically requires many months. There are many circumstances, however, where the rapid production, release, and delivery of these biologics could address unmet medical needs, including shortages, emergency situations, and pandemics. This talk will present a new platform developed to produce biologic medicines on demand called Integrated and Scalable Cyto-Technology (InSCyT). This platform comprises an integrated, subliter-scale portable system for the (semi)continuous operation of fermentation, filtration of cell debris from secreted product, innovative affinity-based purification, polishing, and finishing. This program also emphasizes integrated …

Regulatory Challenges Of Continuous Biomanufacturing, Andy Papas

Integrated Continuous Biomanufacturing II

The interaction with regulatory agencies on the biomanufacturing of therapeutic proteins, mAbs, or other large molecules occurs throughout the drug development of the biologic; it begins with the original IND, accelerates at the licensing phase and continues throughout the product’s life cycle. There are many regulatory challenges along this journey.

Because of uniqueness of continuous biomanufacturing, one challenge that occurs throughout the product’s lifecycle is the inevitable change in Agency product reviewers who many times need to be educated on the nuances of your process or have a different opinion or expectation on how things should be done. As such, …

Design And Control Of Chromatography Step In An Integrated Column Sequence, Bernt Nilsson, Niklas Andersson, Anders Holmqvist, Anton Sellberg, Peter Tiainen, Arne Staby

Integrated Continuous Biomanufacturing II

Integration of the purification steps in downstream processing is one way to minimize the number of storage tanks and reduce hold-up time. The result is an integrated column sequence that performs straight through processing of the target protein, with minimal time from expression to formulation. This paper discusses the overall integration design and its expected performance, together with a more detailed analysis of the step behavior based on column simulations. The optimal design of the individual steps in the sequence is presented, both with robustness margins and local control system, as well as with and without local recycle.

An optimization …

Integrated Continuous Processing For The Manufacture Of Monoclonal Antibodies, Daniel Karst, Fabian Steinenbach, Massimo Morbidelli

Integrated Continuous Biomanufacturing II

Continuous manufacturing is currently being considered by the Biopharmaceutical Industry not only for the classical reasons which make continuous operation preferred over the batch one, but also for recent initiatives of the regulatory agencies. We discuss here a series of experiments where a perfusion reactor with CHO cells for the production of a monoclonal antibody has been operated in the continuous mode and connected to a two column continuous protein A chromatographic unit for product capture. A few steady states are examined and the use of simulation models for process design and control is illustrated.

Integrated Continuous Bioprocessing – Opportunities And Challenges, Mats Akesson, Martin Heitmann, Ditte Skipstrup, Peter Tiainen

Integrated Continuous Biomanufacturing II

We have developed an integrated continuous processing framework for end-to-end production of complex fragile proteins based on perfusion cultivation and automated multi-step purification [1,2,3]. Upstream, the integrated system consists of a stirred tank bioreactor with an ATF cell retention system. The clarified harvest directly enters an off-the-shelf ÄKTA chromatography system converted into a continuous purification unit. Two alternating capture columns precede an automated multi-step purification train with full flexibility and control of individual columns.

The integrated set-up enables compact automated bench-top factories converting cell culture media to purified protein in an efficient manner without intermediate storage. It provides monitoring of …

Continuous Culture And Downstream Processing Of Algae With Recycle: An Integrated Large-Scale Approach For Production Of Renewable Crude Oil, Matt Croughan

Integrated Continuous Biomanufacturing II

In order to have a significant impact on energy security and reduction of greenhouse gasses, the production of advanced biofuels must be increased to billions of gallons per year. Scale up of phototrophic algae bioprocessing for renewable oil production has been attempted for decades and has recently reached new levels of performance and scale. For over three years, Sapphire has successfully operated the world’s largest algae farm, consisting of 100 acres of ponds in New Mexico, used to feed an integrated conversion and extraction unit based on high temperature liquefaction technology. All aspects of the process are run on a …

Continuous Beer Production Methods: A Review Of Chances And Risks, Konrad Müller-Auffermann

Integrated Continuous Biomanufacturing II

Beer brewing is one of the oldest biotechnological processes applied by humans. The production methods are comparatively complex and time consuming, which is the reason why inventors and scientists have steadily attempted to improve its manufacturing.

During the industrial revolution more and more processes where done continuously in order to increase production efficiency. Breweries where trying to modify the classical batch modes into a continuous production process but were unsuccessful. Nearly all approaches failed due to changes of the beer quality.

The presentation shall give a brief overview of different continuous production concepts tested in the past 150 years. Furthermore …

Laboratory Scale Continuous Linear Purification As A Development Tool For Recombinant Blood Protein Processing, Using Chromatographic Resins And Membranes, Michael Hughson, Rimenys Carvalho, Thaynna Araujo Cruz, Leda Dos Reis Castilho

Integrated Continuous Biomanufacturing II

Continuous processing offers significant advantages for the processing of unstable recombinant products such as therapeutic plasma proteins. As such we have established a development platform to assess potential purification steps as part of a continuous linear process using a standard AKTA Explorer. Following a consistent format of IEX membrane to HIC membrane to affinity resin, we were able to rapidly investigate multiple purification pathways for a recombinant blood protein. Using membranes as the first two steps enables a 3-step purification process to be carried out in 3 to 4 hours, with a total turnaround of 5 to 6 hours including …

Continuous Countercurrent Tangential Chromatography For Purification Of High Value Therapeutic Proteins, Andrew Zydney, Oleg Shinkazh, Boris Napadensky, Amit Dutta

Integrated Continuous Biomanufacturing II

One of the main challenges in the development of integrated continuous processes for the production of high value therapeutic proteins is the replacement of traditional column chromatography, which tends to dominate current downstream processing. Continuous Countercurrent Tangential Chromatography (CCTC) has been designed to provide truly continuous product capture and purification using a column-free system that overcomes many limitations of traditional column chromatography. All operations in CCTC are conducted on a moving slurry that is continuously pumped through a cascade of static mixers (for mixing and residence time) and hollow fiber membrane modules (for separation of the fluid phase from the …