Webinar: A novel bioreactor reduces costs per dose by scaling high density hiPSC culture

Scalable expansion of induced pluripotent stem cells (iPSCs) remains a key bottleneck for next-generation
cell therapies, with conventional culture approaches limited in cell density, robustness, and scalability. Fedbatch
processes, while widely used, struggle to maintain optimal nutrient supply and waste removal at
high cell densities. Current bioreactor technology can’t scale high-intensity cell cultures without excessive
foaming and shear force.
This webinar presents the BioThrust 300 mL single-use bioreactor, designed for straightforward operation
in standard incubators or as a closed standalone system. The novel "ComfyCell" bioreactor integrates a
membrane-based Impeller and gas transfer concept that enables controlled fluid dynamics and low-shear
mass transfer. A complete workflow at 300 mL is demonstrated, covering spheroid formation from single
cells, expansion, harvest, and direct scale-up into a 2 L single-use ComfyCell bioreactor.
At both volumes, BioThrust’s in-situ perfusion system and Membrane Stirrer enable significantly improved
culture performance while maintaining full cell quality. Process analytics and cultivation data are
presented, including world record cell densities up to 44×10E6 cells/mL at 300 mL and 11x10E6 cells/mL
at 2 L.
These results illustrate how perfusion-based bioprocessing can enable robust, high-density iPSC manufacturing and support the development of scalable, commercially efficient cell therapy platforms.

About the Speakers:

Dr.-Ing. Patrick Bongartz is the Co-Founder and CEO of BioThrust, where he leads the company's mission to scale cell culture processes with bionic bioreactors for controllable and scalable cell therapy manufacturing.  Dr. Marco Oliveira is a Bioprocess Expert at BioThrust with more than 10 years of experience in biotechnology, specializing in iPSC-derived therapies and scalable bioprocess development