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The field of manufacturing is constantly evolving to reflect innovations in technology and research. A growing number of engineers are now focusing on biomanufacturing, or what it means to construct and grow living systems, such as algae. This evolution emphasizes the need for multidisciplinary collaboration among fields such as biology and engineering, a shift that is underway at the 91����.

At the forefront of this effort is Bashir Khoda, a professor in the Maine College of Engineering and Computing at 91����, whose laboratory conducts research on growing algae cells while simultaneously working to train the next generation of STEM researchers through new education initiatives. 

With a background in manufacturing, Khoda and his team developed an innovative method to grow and harvest algae cells with greater efficiency. Microalgae traditionally are grown in a “soup” of cells floating freely in liquid, but Khoda’s technique places the algae cells in small gel beads, forming what he calls a droplet necklace. Encapsulating the cells in these beads creates a more controlled environment and reduces stress on the cells. 

“We are hypothesizing that this stress-free technique can produce at least 50% more volumetric output than the status quo, allowing us to grow more in a smaller space. Since this is a closed system, quality and consistency are extremely important and can be achieved with this technique,” Khoda said.

This work is made possible by a kickstarter grant from the NSF EPSCoR E-RISE RII-funded Maine Algal Research Infrastructure and Accelerator (MARIA) project, led by Bigelow Laboratory for Ocean Sciences to further his research and educational objectives at 91����. The seed funding is part of a broader effort to advance algae-based solutions and manufacturing to further the blue economy in Maine, positioning the state as a leader in this field. These research projects work to advance the accessibility of algae cultivation while developing innovations that could benefit both human and animal health.  

With support from the kickstarter funding provided by MARIA and Bigelow Laboratory, Khoda’s lab plans to expand their research by scaling the technology for commercial use, training more students in biomanufacturing, and growing laboratory capabilities for further biofabrication and smart manufacturing. 

The field of algae research and development is increasingly used for high-value products in pharmaceuticals, nutraceuticals, and nanomaterials, creating many applications for Khoda’s manufacturing technique. He hopes his methods will help increase the production and output of algae, as part of a broader effort to cultivate sustainable products compared to animal or petroleum-based systems. 

Beyond the biomanufacturing process, Khoda’s lab is part of a broader initiative to expand multidisciplinary work at 91���� and prepare students for the STEM workforce. The educational component of his work focuses on creating more opportunities for research and teaching in smart manufacturing of living systems across science and engineering disciplines. He plans on utilizing this funding to create more interdisciplinary collaboration, experiential learning opportunities, and new courses at 91���� related to biomanufacturing, manufacturing engineering, and digital manufacturing.  

Additionally, Khoda hopes to establish an “Algae Corner” at 91���� as the core of his educational initiative. This space would support hands-on learning, research, and network development in living systems engineering within the Maine College of Engineering and Computing, enhancing workforce development aligned with Maine’s growing bioeconomy. 

With support from the MARIA team, Bigelow Laboratory and new bioengineering facilities in the Ferland Engineering Education and Design Center, Khoda’s research opens new avenues for both biomanufacturing and educating the future STEM workforce.

By Heather Johnson, Graduate Assistant