3D Printing Proteins for Continuous Flow Biocatalysis and Bioabsorbtion

Enzymes are being locked inside 3D-printed hydrogel structures to create continuous-flow chemical reactors that can run without stopping. Most industrial chemical reactions use harsh conditions, toxic solvents, and high energy inputs. Enzymes offer a cleaner alternative, but they are fragile and difficult to recover after use. This project prints enzymes directly into permeable hydrogel scaffolds using a technique called puSLA, then places those scaffolds inside a flow reactor where reactants continuously pass through. The challenge is balancing mechanical strength, pore size, and enzyme activity so the reactor runs efficiently at scale. If the design works, manufacturers could replace batch chemical processes with continuous biocatalysis—cutting energy use, eliminating toxic waste, and recycling expensive cofactors. The same approach could also produce bioabsorbable materials that break down safely inside the body. The research is applied and design-focused: it aims to solve the engineering constraints—product separation, cofactor recycling, flow characteristics—that currently prevent enzyme-based reactors from leaving the lab. Success would mean cleaner pharmaceutical synthesis, greener fine chemical production, and implantable materials that the body can absorb without a second surgery.