Lab Activity 3: Design a Space-Based Drug Manufacturing System

Objective

Students will design and prototype a bioreactor system for producing antibody therapeutics in space, addressing unique microgravity challenges.

Time Required

2-3 class periods (120-180 minutes total)

Materials

• Engineering design notebooks
• Drawing/CAD software (Tinkercad, Fusion 360, or paper)
• Building materials (cardboard, plastic bottles, tubing, etc.)
• Presentation materials
• NASA biomanufacturing research papers

Challenge Statement

Mission: Design a bioreactor system to produce monoclonal antibodies during a Mars mission.

Requirements:
- Operate in microgravity
- Volume: maximum 0.5 m³
- Power: maximum 500W continuous
- Produce 100mg of purified antibody per week
- Minimal crew time (< 2 hours/week maintenance)
- Safe and sterile operation
- Closed-loop system preferred

Constraints:
- Limited water (must recycle)
- No gravity for settling/separation
- Radiation shielding needed
- Temperature control essential
- Must withstand launch vibrations

Background Research (30 minutes)

Key Systems to Research:
1. Cell culture methods (suspension vs. adherent)
2. Nutrient delivery and waste removal
3. Gas exchange without bubbles
4. Temperature control
5. Sterility maintenance
6. Product harvesting and purification
7. Monitoring and control systems

NASA Research:
- ISS biomanufacturing experiments
- Protein crystal growth studies
- 3D bioprinting in space
- Closed-loop life support systems

Design Process

Phase 1: Concept Development (45 minutes)

Brainstorm Solutions:
1. How to culture cells without gravity-driven settling?
2. Gas exchange without bubble formation?
3. Nutrient/waste management?
4. Harvesting antibodies?
5. Monitoring cell health?

Sketch Ideas:
- Create 3-5 rough concept sketches
- Label key components
- Note advantages and disadvantages of each

Phase 2: Detailed Design (60 minutes)

Select Best Concept and Detail:

Required Components:
1. Cell Culture Chamber
- Material selection
- Volume and geometry
- Cell retention method
- Sampling ports

1. Fluid Management
2. Pump type
3. Flow rates
4. Filter systems

5. Fluid separation

6. Gas Exchange

7. Oxygen supply
8. CO2 removal
9. Membrane vs. sparging

10. Pressure control

11. Temperature Control

12. Heating/cooling method
13. Temperature sensors

14. Insulation needs

15. Monitoring Systems

16. pH sensors
17. Dissolved oxygen
18. Cell density

19. Product concentration

20. Power and Control

21. Power budget
22. Computer control
23. Data logging
24. Alarms and safety

Phase 3: Physical Prototype (45 minutes)

Build Scale Model:
- Use provided materials
- Show key features
- Must demonstrate:
- Fluid flow path
- Gas exchange
- Sampling mechanism
- Basic monitoring

Phase 4: Testing and Iteration (30 minutes)

Test Protocol:
1. Fill with water (simulates cell culture)
2. Demonstrate fluid circulation
3. Show gas exchange
4. Test sampling
5. Identify problems
6. Propose improvements

Deliverables

1. Technical Drawing

• Dimensioned diagram
• Component labels
• Material specifications
• Flow diagrams

2. Design Report

Sections:
- Introduction and requirements
- Background research summary
- Design concept and rationale
- Detailed component descriptions
- Operational procedures
- Safety considerations
- Testing results
- Limitations and future improvements
- Cost estimate
- References

3. Physical Prototype

• Scale model (non-functional acceptable)
• Labels for key components
• Demonstration of key concepts

4. Presentation (10 minutes)

• Problem statement
• Design solution
• Key innovations
• Test results
• Q&A

Evaluation Criteria

Technical Design (40 points)
- Meets all requirements
- Addresses microgravity challenges
- Innovative solutions
- Feasibility

Documentation (30 points)
- Clear technical drawings
- Complete design report
- Research citations
- Professional quality

Prototype (20 points)
- Demonstrates key concepts
- Build quality
- Functionality

Presentation (10 points)
- Clarity and organization
- Technical depth
- Team participation
- Responses to questions

Example Solutions to Discuss

Rotating Wall Vessel:
- Cells kept in suspension by rotation
- Low shear stress
- Used by NASA for tissue engineering

Hollow Fiber Bioreactor:
- Cells in compartment
- Nutrients/waste through semi-permeable fibers
- High cell density
- Compact design

Perfusion Bioreactor:
- Continuous media flow
- Cell retention with filter
- Waste removal
- Product harvesting

Safety Considerations

Biological Safety:
- Containment of cell culture
- Sterilization procedures
- Waste disposal

Chemical Safety:
- Media and buffer handling
- pH control chemicals
- Antibody purification reagents

Mechanical Safety:
- Pressure vessel design
- Pump safety
- Leak prevention

Extensions

Advanced Challenges:
1. Design downstream purification system
2. Add real-time product quality monitoring
3. Integrate with spacecraft life support
4. Scale up to industrial production
5. Design for lunar gravity (1/6 g)

Career Connections:
- Bioprocess engineer
- Spacecraft systems engineer
- Biotechnology product development
- Space manufacturing specialist

Resources

NASA Research

• "Biomanufacturing in Low Earth Orbit" papers
• ISS National Lab biomanufacturing projects
• NASA Technology Roadmaps

Industry Examples

• Space Tango bioreactor
• Techshot ADvanced Space Experiment Processor (ADSEP)
• Lambda Biotech systems

Technical References

• Bioprocess Engineering textbooks
• Pharmaceutical manufacturing guidelines
• NASA systems engineering handbook

Teacher Notes

Preparation:
- Gather building materials
- Print technical specifications
- Set up presentation area
- Invite guest engineer if possible

Facilitation Tips:
- Encourage creative thinking
- Emphasize iterative design
- Connect to real NASA projects
- Allow failure and learning

Assessment:
- Use rubric consistently
- Provide feedback during design process
- Encourage peer review
- Document with photos/videos

Time Management:
- Day 1: Research and concept (75 min)
- Day 2: Detailed design and prototype (90 min)
- Day 3: Testing and presentations (90 min)

Part of the Space Medicine Antibody Drug Development Curriculum
Engineering Design Standards: NGSS HS-ETS1-2, HS-ETS1-3