MEM 688 Final Project
Concurrent Engineering of a
Bioreactor Design
Modified Marine Impeller
Customer Inputs, with Process and Output
Input
(Customer Needs)
Process
(Concurrent Engineering)
Output
(RP for lab Testing and Full
Scale Manufacture)
Want Sanitary Agitator for
processing with Cell Culture
(Sterile environment)
Design with no gaps, must
have no collection points for
water buildup; FEA, Detailed
Design and Parts Assembly,
Mechanism Animation and STL
for RP
EPDM 0-rings,
No gaps,
all welds done with 316L SS,
Material 316L, for corrosion
resistance, All Points are self
draining
<15 Ra surface Finish
STL for RP for Lab and Full
Scale Manufacture
Maximum Mixing Capacity,
Minimum Blend Time and
Required Vessel Turnover
Design Most amount of
turnover of liquid columns,
Determine estimated blend
time and required vessel
turnover with impeller design
Greatest turnover of liquid for
most effective use for getting
nutrients to cell growth
Minimum Energy with Most
efficient Mixing
Use of Marine Impeller design
Marine Impeller design placed
at lower and upper liquid level
(Downpumping)
Maximize Mass Transfer
Get Maximum Kla
Downpumping ensures that
oxygen and air is kept in liquid
CE Wheel for Handling Process
Mechanism Animation
(MK/PV – Wk 9)
Finite Elemental
Analysis
(JDL/PV – Wk 8)
Product
Development
(JDL/MK/PV)
Detailed & Assembly
Drawings
(MK WK 4-9)
STL File for Rapid
Prototyping
(PV – WK 8)
Bioreactor and Fermentation Design
At the beginning of the project, the team determined that the following
parameters would be used throughout the design:
Poisson’s ratio n= 0.31 for 316L stainless steel
Surface Finish: electropolished <15 Ra or better
Young’s Modulus E = 150 GPa, or 21.75M75 x 106 lbs./in2
Geometric Dimensions and Tolerance must be +/- 0.010”
Design would be smooth and sanitary to prevent any type of pooling
of water as this would need to be used in a sterile bioreactor
Agitator would spin up to 100 RPM using a 3 hp motor.
– Agitator would fit into Bioreactor, see Figure 3 and fit into Mechanical
Seal and Gear Box.
The forces imposed on agitator and mechanical seal while in splash
zone (e.g. liquid level is in the midway point of the impeller and
excessive waves or extra splashing and slapping of the impellers puts
undue stress on shaft, mechanical seal and impellers) would be
neglected.
CE Benefits
Original Cost to Manufacture: $65,000
New Project Cost to Manufacture: $55,000
15% reduction
Time to Manufacture: 16 Weeks
New Time to Manufacture: 11 weeks
31% reduction of time
Typical Time for Product Development: 12 weeks
Time for Product Development for this CE Project: 6 weeks
50% reduction in product development time
Quality of Part increased based on customer feedback to meet project
needs and product usage – 100%
Scrap and Re-work reduced by 10%
Design Details
Design Details
Detailed Design
FEM Analysis Displacement
FEM Analysis Displacement
FEM Analysis Displacement
STL file Format for RP
Movie and Animation of Part