Potential risks associated with extractables and leachables from 3D printed columns evaluated.

3D printed columns functionalised with protein A and SO3 ligands for use in mAb capture and polishing.

Successful mAb captured with recovery yield > 85 % and 70 % in affinity and cation exchange mode, respectively.

Negligible leakage of protein A from 3D printed column and unchanged column performances over 20 cycles.

High HCP clearance (log reduction ∼ 2.7) demonstrated with no formation of aggregates.

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.

3D printing

Affinity chromatography

Protein A

Monoclonal antibody

Downstream processing

Data will be made available on request.

© 2024 The Author(s). Published by Elsevier B.V.