AI-supported monitoring of 3D cell aggregate growth in suspension-based bioreactors.
Fraunhofer researchers have developed an intelligent sensor and AI-based system to continuously monitor and optimize the production of stem cell-based 3D tissue models in bioreactors. The solution enables real-time quality control throughout the manufacturing process, reducing the risk of wasted time and materials and opening up new opportunities for biotech and pharmaceutical applications beyond animal-free drug testing.
Developed jointly by the Fraunhofer Institutes IBMT and IZFP at the Fraunhofer Center for Sensor Intelligence ZSI, the system combines electrochemical sensors, optical cameras and edge AI. It monitors key parameters such as glucose, oxygen, pH and temperature, while cameras analyze the size, number and quality of cell spheroids in real time. All data are processed locally by the modular MAUS sensor platform, ensuring objective, automated quality assessment without damaging or labeling the cells.
The cloud-independent system meets strict data security requirements and complies with modern regulatory concepts such as Process Analytical Technology (PAT) and Continuous Process Verification. Thanks to its modular design, it can be easily adapted to different research and industrial production scenarios. The solution is already in successful use at Fraunhofer ZSI and will be presented at Analytica 2026 in Munich.