In-Fermenter Cell Datastreams: Wireless Networks of Free-Floating Microbial-Electronic Sensors 

Members: Boston University, Capra Biosciences  

Project dates: 2026 – present

This project will develop a smart sensing system to monitor industrial fermentation tanks in real time. This approach uses a network of sensors that float freely inside the tanks to provide high-quality data with precise time and location information. This research will generate a new type of datastream from industrial bioreactors to enable predictive artificial intelligence (AI) and machine learning (ML) for fermentation optimization. It addresses a critical challenge in scaling bioindustrial manufacturing: the lack of cost-effective, continuous, in situ data necessary for adaptive process control, especially when using variable, locally sourced carbon feedstocks, such as agricultural waste and anaerobic digestate. 

As these feedstocks grow in availability and importance, their shifting chemical profiles can unpredictably impact microbial metabolism, making it difficult to maintain consistent productivity at scale. This project proposes an innovative solution: a secure, free-floating sensor network that operates within bioreactors and wirelessly streams rich data in real time. 

This platform is unique because it integrates two key innovations: miniaturized, low-power Complementary Metal-Oxide Semiconductor (CMOS)-based electrochemical sensor arrays to monitor redox state, media composition, and cell health; and whole-cell biosensors in Yarrowia lipolytica to report on intracellular stress and metabolite levels. The resulting high-resolution data feeds into an AI/ML framework for digital twins, adaptive control, and predictive biomanufacturing. 

This research will be used to create a scalable, modular data infrastructure for real-time bioprocess monitoring and control. The platform will be validated in manufacturing-scale bioreactors at Capra Biosciences, demonstrating its potential to reduce development cycles, increase strain robustness, and enable autonomous biomanufacturing. 

By introducing a novel wireless sensor network and generating rich, multidimensional datasets, this project will empower BioMADE members to accelerate innovation, enhance process reliability, and reduce operational risks, strengthening the broader bioindustrial manufacturing industry and enabling mission-critical applications in both commercial and defense sectors. 

Funding source: U.S. Department of Defense