MIT Engineers Develop Innovative Bubble System to Improve Bioreactor Efficiency

On October 15, 2025, engineers at the Massachusetts Institute of Technology (MIT) introduced a novel system that utilizes electrochemically generated bubbles to detach cells from bioreactor surfaces. This innovation addresses the persistent issue of cell adhesion, which has long impeded efficiency in industries such as biomanufacturing, pharmaceuticals, and biofuel production.

Cell adhesion within bioreactors often leads to operational inefficiencies. In photobioreactors used for algae cultivation, for example, adhered cells can obstruct light penetration, necessitating frequent shutdowns for cleaning—sometimes as often as every two weeks. Traditional methods to mitigate this issue include mechanical scraping, chemical treatments, or enzymatic processes, each with drawbacks such as potential cell damage, high costs, or environmental concerns.

The MIT team's solution involves generating bubbles directly on the surfaces where cells adhere. By applying an electric current, water is split into hydrogen and oxygen gases, forming bubbles that create shear forces sufficient to detach cells without harming them. A key advancement in this system is the separation of the anode from the cell culture medium using a special membrane that only allows protons to pass through. This design prevents the formation of harmful byproducts like bleach, which can occur when sodium chloride in the medium interacts with the anode.

The researchers tested their system by allowing algae cells to adhere to a glass surface coated with a thin layer of gold, ensuring light penetration. Upon applying voltage, bubbles formed, detaching the cells effectively. Further experiments demonstrated that the system works across various cell types, including sensitive mammalian cells, without compromising cell viability.

Professor Kripa Varanasi, the senior author of the study, emphasized the scalability and versatility of the system, stating, "This is a fundamental issue with cells, and we’ve solved it with a process that can scale. It lends itself to many different applications."

This technology holds promise for multiple industries:

• Biomanufacturing and Pharmaceuticals: Enhancing the efficiency of cell culture processes, reducing waste, and improving the production of biologic drugs and cell therapies.
• Biofuel Production: Facilitating the harvesting of algae and other microorganisms used in biofuel generation.
• Environmental Impact: Accelerating the growth of carbon-absorbing algae, contributing to climate change mitigation efforts.

The use of electrochemical methods in bioreactors is not entirely new. For example, previous studies have explored electrolysis electrodes integrated into bioreactors to study electrochemical effects and electricity-aided bioprocesses. However, the MIT system's unique approach of generating bubbles directly on adhesion surfaces without producing harmful byproducts sets it apart from prior methods.

The MIT engineers' development of an electrochemically driven bubble system to detach cells from bioreactor surfaces represents a significant advancement in bioprocessing technology. By addressing the longstanding challenge of cell adhesion, this innovation has the potential to enhance efficiency and sustainability across various industries, from pharmaceuticals to environmental management.