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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 451 records · Page 25
All sourcesNASA NTRSDOE OSTI
DOE OSTI2020

Systematic Analysis of Drivers and Barriers of Cross-Sectorial Learning Between Nuclear and Oil and Gas Decommissioning Projects - 20139

Project and megaproject management in the energy sector have historically focused on the planning and delivery of the construction of infrastructure. Therefore, policies are predominantly oriented to support the construction of infrastructure rather than its decommissioning. However, globally, several facilities have reached (or will soon reach) their end-of-life and need to be decommissioned. These facilities span across the energy sector, including nuclear power plants and oil and gas rigs, whose decommissioning present unprecedented techno-socio-economic challenges. Moreover, globally, their decommissioning cost is estimated to reach hundreds of billions of US dollars and this budget keeps increasing, with limited knowledge-transfer across industries to mitigate the spiraling increase of this figure. Cross-sectorial knowledge-transfer is a way to tackle this matter and improve the planning and delivery of decommissioning and waste management projects. The aim of this research is to build a road-map based on cross-sectorial industrial experience, designed to promote the sharing of good practices between projects both within and across industries dealing with major decommissioning and waste management challenges. To reach this aim, the tacit knowledge of senior practitioners on several large scale nuclear and oil and gas decommissioning projects is made explicit by the means of semi-structured interviews, systematically analyzed through directed content analysis. The results of this analysis include a list of good practices that could and should be transferred to nuclear decommissioning projects, including the need to promote the adoption of incentives explicitly linked to the project deliverables, and to develop long-term plans to support smooth transition from operations to decommissioning. Suggestions about how the knowledge-transfer can be promoted within and across organizations are also discussed. In this way, this research provides practical guidance for project managers and policymakers on how to support the planning and delivery of projects with improved performance. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2020

Modular, Mobile Systems for the Treatment of Contaminated Water at Three Magnox Sites in the United Kingdom - 20421

Veolia Nuclear Solutions (VNS), and its mitigated entity, Veolia Nuclear Solutions Federal Services (VNSFS), are designing, overseeing the fabrication and installation, and supporting the commissioning of highly mobile and modular skid-based water treatment systems to assist in the decommissioning of three Magnox reactor sites based in the U.K. These Modular Active Effluent Treatment Plants (MAETP) will be deployed at the Chapelcross, Hinkley Point A, and Dungeness A sites to process contaminated water through the use of ion exchange systems and/or filtration units. At the time of writing, two systems have been installed and inactively commissioned, and the third system is expected to be delivered in 2020. Veolia has utilized a multi-national team of engineers, based in the UK and the US, to effectively leverage the best of Veolia expertise in the design and delivery of mobile, modular systems. The VNS team continues to refine the modular, mobile, and scalable approach to water processing system delivery, and has successfully patented the evolving technology for proprietary protection. The intent of this technology investment is to improve the functionality, mobility, and modularity, resulting in a system which can be adapted to a broad range of throughput and isotope removal requirements to achieve the most cost effective, flexible system possible for customers. Designing, fabricating, and factory-testing the modules off site followed by onsite installation, testing, start-up, and commissioning ensures expedited delivery and setup, as well as cost savings for nuclear applications. For the MAETP systems, VNS's previous nuclear site experience and ongoing Research and Development (R and D), combined with the resulting mobile/modular water processing systems developed and successfully deployed by VNS, have proven to be important inputs for the successful end-design of the systems, materials selection, system testing and commissioning. The lessons learned in the development and continued enhancement of the patented systems described in this paper will prove useful in advancing and deploying future systems for other nuclear sites, where rapid customizing and cost-effective implementation are critical factors. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2026

Analysis of Slow Spill Data for the Mu2e Experiment

The execution of the Mu2e experiment requires a stable, low-intensity proton beam from the Delivery Ring to produce clean data and protect equipment. This is done by performing a “slow extraction,” which is the gradual contraction of the stable region within the accelerator’s beam pipe. The Delivery Ring is currently unable to perform slow extraction with the stability required by Mu2e. To resolve this, the FAN-C team is training machine learning models with the purpose of replacing the Delivery Ring’s current PID controllers with AI-powered controllers. Training these models requires clean, processed data from slow spills. Over the course of this project, data from previous slow spills were processed and analyzed, and the clean data, graphs, and insights gained from the process were provided to the FAN-C team to assist them in their efforts.

Osborn, Thomas [Purdue U., West Lafayette]↗
DOE OSTI2022

Deep Learning‐Assisted Automated Single Cell Electroporation Platform for Effective Genetic Manipulation of Hard‐to‐Transfect Cells

Abstract Genome engineering of cells using CRISPR/Cas systems has opened new avenues for pharmacological screening and investigating the molecular mechanisms of disease. A critical step in many such studies is the intracellular delivery of the gene editing machinery and the subsequent manipulation of cells. However, these workflows often involve processes such as bulk electroporation for intracellular delivery and fluorescence activated cell sorting for cell isolation that can be harsh to sensitive cell types such as human‐induced pluripotent stem cells (hiPSCs). This often leads to poor viability and low overall efficacy, requiring the use of large starting samples. In this work, a fully automated version of the nanofountain probe electroporation (NFP‐E) system, a nanopipette‐based single‐cell electroporation method is presented that provides superior cell viability and efficiency compared to traditional methods. The automated system utilizes a deep convolutional network to identify cell locations and a cell‐nanopipette contact algorithm to position the nanopipette over each cell for the application of electroporation pulses. The automated NFP‐E is combined with microconfinement arrays for cell isolation to demonstrate a workflow that can be used for CRISPR/Cas9 gene editing and cell tracking with potential applications in screening studies and isogenic cell line generation.

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2022

Predicting transport of intra-articularly injected growth factor fusion proteins into human knee joint cartilage

There are no drugs or treatment methods known to prevent the development of post-traumatic osteoarthritis (PTOA), a type of osteoarthritis (OA) that is triggered by traumatic joint injuries and accounts for ~12% of the nearly 600 million OA cases worldwide. Lack of effective drug delivery techniques remains a major challenge in developing clinically effective treatments, but cationic delivery carriers can help overcome this challenge. Scaling up treatments that are effective in in vitro models to achieve success in preclinical in vivo models and clinical trials is also a challenging problem in the field. Here we use a cationic green fluorescent protein (GFP) as a carrier to deliver Insulin-Like Growth Factor 1 (IGF-1), a drug considered as a potential therapeutic for PTOA. GFP-IGF-1 conjugates were first synthesized as fusion proteins with different polypeptide linkers, and their transport properties were characterized in human cartilage explants. In vitro experimental data were used to develop a predictive mathematical transport model that was validated using an independent in vitro experimental data set. In this study, the model was used to predict the transport of these fusion proteins upon intra-articular injection into human knee joints. The predictions included results for the rate and extent of fusion protein penetration into cartilage, and the maximum levels of fusion proteins that would escape into systemic circulation through the joint capsule. Together, our transport measurements and model set the stage for translation of such explant culture studies to in vivo preclinical studies and potentially clinical application.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Understanding interactions between biomolecules and two-dimensional nanomaterials using in silico microscopes

We report two-dimensional (2D) nanomaterials such as graphene are increasingly used in research and industry for various biomedical applications. Extensive experimental and theoretical studies have revealed that 2D nanomaterials are promising drug delivery vehicles, yet certain materials exhibit toxicity under biological conditions. So far, it is known that 2D nanomaterials possess strong adsorption propensities for biomolecules. To mitigate potential toxicity and retain favorable physical and chemical properties of 2D nanomaterials, it is necessary to explore the underlying mechanisms of interactions between biomolecules and nanomaterials for the subsequent design of biocompatible 2D nanomaterials for nanomedicine. The purpose of this review is to integrate experimental findings with theoretical observations and facilitate the study of 2D nanomaterial interaction with biomolecules at the molecular level. We discuss the current understanding and progress of 2D nanomaterial interaction with proteins, lipid membranes, and DNA based on molecular dynamics (MD) simulation. In this review, we focus on the 2D graphene nanosheet and briefly discuss other 2D nanomaterials. With the ever-growing computing power, we can image nanoscale processes using MD simulation that are otherwise not observable in experiment. We expect that molecular characterization of the complex behavior between 2D nanomaterials and biomolecules will help fulfill the goal of designing effective 2D nanomaterials as drug delivery platforms.

2D nanomaterials↗
DOE OSTI2022

Utilizing commercial heating, ventilating, and air conditioning systems to provide grid services: A review

The modern power grid faces multiple challenges due to an increase in the adoption of renewable generation, such as dynamically balancing supply and demand at different time scales. Demand side management in buildings plays a vital role in achieving this balance because buildings can provide grid services through a variety of building assets. However, the development of grid-interactive, efficient buildings is still in its infancy, and a systematic and holistic understanding of grid service delivery strategies in terms of energy efficiency, load shifting, load shedding and load modulating is still limited. This paper is a comprehensive review of the development and application of building-level control strategies for utilizing heating, ventilating, and air conditioning systems to provide grid services. These strategies have been investigated through numerical and experimental studies. Control algorithms, such as heuristic rule-based control and model-based control, have been used to enable the automatic control delivery of grid services. The advantages and disadvantages of the strategies are summarized and discussed. Finally, research trends are also identified, which include considering predicted mean vote-based and occupant-based thermal comfort, modeling of occupant behavior, integrating power grid operations with building control, and combining different demand flexibility modes in the control design.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2022

Effect of cholesterol on nano-structural alteration of light-activatable liposomes via laser irradiation: Small angle neutron scattering study

Although the light-activated liposomes have been extensively studied for drug delivery applications, the fundamental mechanism of the drug release based on lipid compositions has not been fully understood. Especially, despite the extensive use of cholesterol in the lipid composition, the role of cholesterol in the light-activated drug release has not been studied. Here, in this study, the influence of cholesterol on drug release from light-responsive drug-encapsulated liposomes after activated by near infrared (NIR) laser was investigated. We prepared methotrexate (MTX)-encapsulated DSPC liposomes consisting of 0 mol% (—Chol) or 35 mol% cholesterol (+Chol), with (+Au) or without gold nanorods (—Au) on the lipid bilayer to compare drug release, morphological changes, and nanostructures after laser irradiations. Transmission electron microscopy (TEM) and small angel neutron scattering (SANS) data revealed that only +Chol +Au liposomes showed partial aggregation of the liposomes after laser irradiation. Similar trends on the drug release and structural change were observed when the liposomes were heated to above chain-transition temperature. Overall, we have found that (1) inclusion of 35 mol% cholesterol enhanced the permeability of lipid bilayers above T c ; (2) the mechanism of laser-activated liposomal drug delivery is disrupting lipid bilayer membranes by the photothermal effect in the presence of plasmonic materials. By understanding the fundamentals of the technology, precise controlled drug release at a targeted site with great stability and repeatability is anticipated.

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2022

Joint routing of conventional and range-extended electric vehicles in a large metropolitan network

Range-extended electric vehicles combine the higher efficiency and environmental benefits of battery-powered electric motors with the longer mileage and autonomy of conventional internal combustion engines. This combination is particularly advantageous for time-constrained delivery routing in dense urban areas, where battery recharging along routes can be too time-consuming to economically justify the use of all-electric vehicles. However, switching from electric to conventional fossil fuel modes also results in higher costs and emissions and lower efficiency. This paper analyzes this heterogeneous vehicle routing problem and describes two solution methods: an exact branch-price-and-cut algorithm and an iterated tabu search metaheuristic. From a methodological perspective, we find that the exact algorithm consistently obtains tight lower bounds that also serve to certify the metaheuristic solutions as near-optimal. From a policy standpoint, we examine a large-scale real-world case study concerning parcel deliveries in the Chicago metropolitan area and quantify various operational metrics including energy costs and vehicle miles traveled. We find that by deploying roughly 20% of range -extended vehicles with a modest all-electric range of 33 miles, parcel distributors can save energy costs by up to 17% while incurring less than 0.5% increase in vehicle miles traveled. Increasing the range to 60 miles further reduces costs by only 4%, which can alternatively be achieved by decreasing the average service time by 1 minute or increasing driver working time by 1 hour. In conclusion, our study reveals several key areas of improvement on which vehicle manufacturers, distributors, and policy makers can focus their attention.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2026

N -Terminal Octylated Peptoid Hydrogels as 3D-Printable Cell Scaffolds and Proteolytically Robust Cargo Depots

Supramolecular hydrogels that mimic the extracellular matrix (ECM) represent promising materials for tissue engineering and drug delivery. However, conventional hydrogels formed via the self-assembly of natural or synthetic building blocks often face a trade-off between biological functionality and biochemical stability, limiting their utility in long-term or protease-rich environments. Peptoids, a class of peptide-inspired, sequence-defined polymers, offer a compelling alternative due to their exceptional proteolytic resistance and bioactivity. Despite this potential, the development of supramolecular peptoid hydrogels has been hindered by the absence of backbone hydrogen bond donors, which limits long-range ordering necessary for efficient hydrogel formation. This work describes a short peptoid functionalized at the N-terminus with an octyl chain that readily self-assembles into hydrogels. Hydrophobic interactions among pendant octyl groups promote directional peptoid packing into highly ordered nanosheets, which interconnect to form a porous hydrogel network. These hydrogels exhibit tunable viscoelasticity, shear-thinning, and self-healing properties, enabling their use as inks for extrusion-based 3D printing. They support NIH-3T3 fibroblast adhesion, spreading, and proliferation, maintaining greater than 95% cell viability over 4 days. Moreover, the hydrogels retain their macroscopic integrity under protease-rich conditions, enabling sustained cargo release and uniform cellular uptake. Together, this study demonstrates a class of supramolecular peptoid hydrogelators that integrate biocompatibility, 3D printability, and proteolytic stability, providing a versatile platform for ECMmimetic scaffolds in regenerative medicine and long-term therapeutic delivery.

cargo delivery↗
DOE OSTI2022

Mechanism of endosomal escape by p H -responsive nucleic-acid vectors

Successful intracellular delivery of nucleic acids (NAs) hinges on many factors, one of them being NAs’ efficacious escape from endosomes. As competent NA vectors, pH-responsive gemini surfactants (GSs) might achieve high efficacy by facilitating endosomal escape. However, how the GSs assist the escape remains debated as many proposed mechanisms still lack experimental support, which hinders replication and further improvement of the efficient delivery. Here, via UV, fluorescence spectroscopy, and small-angle neutron scattering (SANS), we examined a pH-responsive GS's and a pH-unresponsive GS's capabilities to compact DNA and withstand binding competition, and their interactions with model endosomal and lysosomal membranes, at varied pHs. Acidification-driven enhancement of DNA-compaction capability and of stability against binding competition were found specific to the pH-responsive GS. Alongside the pH-responsive GS's structural perturbation to the membranes as observed with SANS, the features suggest that pH-responsive GSs facilitate endosomal escape by releasing excess GS molecules from DNA-GS complexes upon acidification in endosome maturation, with the released GS molecules disrupting endosomal and lysosomal membranes and thereby assisting the escape. Here a general design principle for NA vectors is proposed on the basis of this experimental finding.

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2021

Serial crystallography using automated drop dispensing

Automated, pulsed liquid-phase sample delivery has the potential to greatly improve the efficiency of both sample and photon use at pulsed X-ray facilities. In this work, an automated drop on demand (DOD) system that accelerates sample exchange for serial femtosecond crystallography (SFX) is demonstrated. Four different protein crystal slurries were tested, and this technique is further improved here with an automatic sample-cycling system whose effectiveness was verified by the indexing results. Here, high-throughput SFX screening is shown to be possible at free-electron laser facilities with very low risk of cross contamination and minimal downtime. The development of this technique will significantly reduce sample consumption and enable structure determination of proteins that are difficult to crystallize in large quantities. This work also lays the foundation for automating sample delivery.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗
DOE OSTI2023

On-Chip Batteries as Distributed Energy Sources in Heterogeneous 2.5D/3D Integrated Circuits

Energy efficiency in digital systems faces challenges due to the constraints imposed by small-scale transistors. Moreover, the growing demand for portable consumer electronics necessitates the use of compact energy sources. To address these challenges, heterogeneous 3D IC technology has emerged as a promising solution for the former. Regarding the latter, we propose the concept of distributed batteries within a heterogeneous 3D IC. This approach involves utilizing multiple smaller batteries with different specifications among different modules of 3D ICs. This approach optimizes performance and overcomes limitations associated with both 3D ICs and conventional power delivery methods. Distributed batteries play a vital role in effectively managing the heat generated by energy sources and modules within a 3D IC. Furthermore, they contribute to achieving a uniform distribution of heat throughout the entire structure, which ultimately ensures the optimal performance of the batteries and modules. The simulation results indicate a 40 percent enhancement in achieving a more even distribution of generated heat. Additionally, the proposed distributed battery techniques improve power delivery, enhance reliability, and enable optimized voltage regulation while improving efficiency. In addition to the primary benefits, alternative configurations of the proposed approach can offer extra energy storage capacity and act as efficient electromagnetic shields, resulting in an impressive reduction of external electromagnetic noises by 60 dB.

47 OTHER INSTRUMENTATION↗
DOE OSTI2021

Carbon nanotube biocompatibility in plants is determined by their surface chemistry

Abstract Background Agriculture faces significant global challenges including climate change and an increasing food demand due to a growing population. Addressing these challenges will require the adoption of transformative innovations into biotechnology practice, such as nanotechnology. Recently, nanomaterials have emerged as unmatched tools for their use as biosensors, or as biomolecule delivery vehicles. Despite their increasingly prolific use, plant-nanomaterial interactions remain poorly characterized, drawing into question the breadth of their utility and their broader environmental compatibility. Results Herein, we characterize the response of Arabidopsis thaliana to single walled carbon nanotube (SWNT) exposure with two different surface chemistries commonly used for biosensing and nucleic acid delivery: oligonucleotide adsorbed-pristine SWNTs, and polyethyleneimine-SWNTs loaded with plasmid DNA (PEI-SWNTs), both introduced by leaf infiltration. We observed that pristine SWNTs elicit a mild stress response almost undistinguishable from the infiltration process, indicating that these nanomaterials are well-tolerated by the plant. However, PEI-SWNTs induce a much larger transcriptional reprogramming that involves stress, immunity, and senescence responses. PEI-SWNT-induced transcriptional profile is very similar to that of mutant plants displaying a constitutive immune response or treated with stress-priming agrochemicals. We selected molecular markers from our transcriptomic analysis and identified PEI as the main cause of this adverse reaction. We show that PEI-SWNT response is concentration-dependent and, when persistent over time, leads to cell death. We probed a panel of PEI variant-functionalized SWNTs across two plant species and identified biocompatible SWNT surface functionalizations. Conclusions While SWNTs themselves are well tolerated by plants, SWNTs surface-functionalized with positively charged polymers become toxic and produce cell death. We use molecular markers to identify more biocompatible SWNT formulations. Our results highlight the importance of nanoparticle surface chemistry on their biocompatibility and will facilitate the use of functionalized nanomaterials for agricultural improvement. Graphical Abstract

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2021

TRUST End-of-Year Report

The objective of the Delivery Environments (DE) Testbeds to Reduce Uncertainties in Simulations and Tests (TRUST) work package is to quantify and help increase confidence in specific areas of computational and experimental capabilities that are applicable to current and future delivery environments. More complete quantification of confidence in experimental and computational capabilities and the sufficient increase of confidence in those capabilities is critical to improving weapons engineering design, qualification, and assessment efforts that are critical to the current and future stockpile. Staff development will include cross-discipline training to provide engineers with experience in both numerical simulations and experimental methods. This work will use and provide feedback on analysis tools and experimental results databases for efficient and responsive engineering which are currently under development: engineering common model framework (ECMF), engineering quantification of margins and uncertainties (EQMU), and the test information management system (TIMS). TRUST includes four testbeds and their associated engineering analysis baseline models (EABMs): 1. contact thermal conductivity (CTC); 2. nonlinear dynamics (ND); 3. sensors in environments for accelerometers (SEA); 4. sensors in environments for fiber optic displacement gages (SEFOD).

42 ENGINEERING↗
DOE OSTI2020

Crystallization of ApoA1 and ApoE4 Nanolipoprotein Particles and Initial XFEL-Based Structural Studies

Nanolipoprotein particles (NLPs), also called “nanodiscs”, are discoidal particles with a patch of lipid bilayer corralled by apolipoproteins. NLPs have long been of interest due to both their utility as membrane-model systems into which membrane proteins can be inserted and solubilized and their physiological role in lipid and cholesterol transport via high-density lipoprotein (HDL) and low-density lipoprotein (LDL) maturation, which are important for human health. Serial femtosecond crystallography (SFX) at X-ray free electron lasers (XFELs) is a powerful approach for structural biology of membrane proteins, which are traditionally difficult to crystallize as large single crystals capable of producing high-quality diffraction suitable for structure determination. To facilitate understanding of the specific role of two apolipoprotein/lipid complexes, ApoA1 and ApoE4, in lipid binding and HDL/LDL particle maturation dynamics, and to develop new SFX methods involving NLP membrane protein encapsulation, we have prepared and crystallized homogeneous populations of ApoA1 and ApoE4 NLPs. Crystallization of empty NLPs yields semi-ordered objects that appear crystalline and give highly anisotropic and diffuse X-ray diffraction, similar to fiber diffraction. Several unit cell parameters were approximately determined for both NLPs from these measurements. Thus, low-background, sample conservative methods of delivery are critical. Here we implemented a fixed target sample delivery scheme utilizing the Roadrunner fast-scanning system and ultra-thin polymer/graphene support films, providing a low-volume, low-background approach to membrane protein SFX. This study represents initial steps in obtaining structural information for ApoA1 and ApoE4 NLPs and developing this system as a supporting scaffold for future structural studies of membrane proteins crystalized in a native lipid environment.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2025

Genetically Controlled Iron Oxide Biomineralization in Encapsulin Nanocompartments for Magnetic Manipulation of a Mammalian Cell Line

Magnetic nanoparticles have proven invaluable for biomechanical investigations due to their ability to exert localized forces. However, cellular delivery of exogenous magnetic agents often results in endosomal entrapment, thereby limiting their utility for manipulating subcellular structures. This study characterizes and exploits fully genetically controlled biomineralization of iron-oxide cores inside encapsulin nanocompartments to enable magnetic-activated cell sorting (MACS) and magnetic cell manipulation. The fraction of MACS-retained cells showed substantial overexpression of encapsulins and exhibited both para- and ferrimagnetic responses with magnetic moments of 10 -15 A m 2 per cell, comparable to standard exogenous labels for MACS. Electron microscopy revealed that MACS-retained cells contained densely packed agglomerates of ≈30 nm iron oxide cores consisting of ultrafine quasicrystalline ordered nuclei within an amorphous matrix of iron, oxygen, and phosphorus. Scanning transmission X-ray microscopy, X-ray absorption spectroscopy, and Raman microspectroscopy confirmed that the iron-oxide species are consistent with ferric oxide (Fe 2 O 3 ). In addition, the encapsulin-overexpressing MACS-retained cells can be manipulated by a magnetic needle and regrown in patterns determined by magnetic gradients. This study demonstrates that the formation of quasicrystalline iron oxide with mixed para/ferrimagnetic behavior in the cytosol of mammalian cells enables magnetic manipulation without the delivery of exogenous agents.

60 APPLIED LIFE SCIENCES↗
DOE OSTI2025

High‐Concentration Antibody Formulation via Solvent‐Based Dehydration

Abstract Although subcutaneous (SC) delivery is the preferred administration route for immunotherapies and other biologics for improved patient compliance and lower healthcare costs, it necessitates high‐concentration antibody formulations. However, high‐concentration antibody solutions face significant instabilities and prohibitively high viscosities. Other approaches for high‐concentration formulations have been developed, including non‐aqueous solutions, which can be irritating or painful, and antibody‐laden hydrogel microparticles, which require centrifugation and are limited to concentrations <300 mg mL −1 . This work presents a new formulation process wherein the antibody is concentrated and encapsulated into hydrogel microparticles via solvent‐based dehydration. The final dosage form is an aqueous particle suspension with a formulation concentration of 360 mg mL −1 . In this process, microparticles are synthesized continuously, and antibody precipitation is realized simultaneously to dehydration, which allows for higher antibody concentrations. Antibody phase behavior and precipitation–dehydration kinetics are analyzed. The antibody is structurally and functionally stable in the microparticle post‐processing and after 4 months. Injectability of the suspension meets clinical standards with glide force <20 N. For the first time, an aqueous antibody formulation at high concentrations comparable to non‐aqueous formulations is presented, ideal for subcutaneous administration. The process is envisioned to be generalizable as a platform for SC delivery in multiple clinical applications.

Zheng, Talia [Department of Chemical Engineering M↗