Programmable Carrier‐Free All‐Enzyme Beads for Modular Continuous‐Flow Biocatalysis

Carrier-free enzyme materials offer maximal catalytic density but are typically limited to monolithic or amorphous architectures with restricted process compatibility. Here, we introduce programmable carrier-free all-enzyme beads as structurally defined, porous biocatalytic particles for modular continuous-flow operation. The beads are generated via droplet-based self-assembly of complementary enzyme building blocks, followed by cryogenic consolidation, yielding mechanically robust and monodisperse protein particles that retain full catalytic competence after drying and rehydration. Using mechanistically distinct model systems, including cofactor-independent decarboxylation and metal-dependent C─C bond formation, we demonstrate stable long-term continuous-flow operation exceeding 80 h and compatibility with biphasic solvent systems at elevated substrate concentrations. Beyond single-enzyme catalysis, the bead architecture accommodates binary cofactor-regenerating assemblies, integrated ternary cascades with dual cofactor recycling, and modular combinations of distinct bead populations enabling sequential nucleotide phosphorylation. Notably, flow-induced restructuring leads to adaptive consolidation of packed beds, enhancing effective catalytic volume without compromising mass transport. By uniting structural programmability, high catalytic density, architectural modularity, and adaptive behavior under flow, carrier-free all-enzyme beads bridge molecular enzyme engineering and reactor design, expanding the materials toolbox for scalable and reconfigurable continuous biocatalysis.

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Publication Details

Journal
Advanced Materials
Published
2026-09-24
DOI
https://doi.org/10.1002/adma.75120
Primary Topic
Enzyme Catalysis and Immobilization
Type
article
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article

Programmable Carrier‐Free All‐Enzyme Beads for Modular Continuous‐Flow Biocatalysis

Kim Wanner, Felix Ott, Christof M. Niemeyer, André Delavault et al.
Advanced Materials
Enzyme Catalysis and Immobilization
article

Programmable Carrier‐Free All‐Enzyme Beads for Modular Continuous‐Flow Biocatalysis

Kim Wanner, Felix Ott, Christof M. Niemeyer, André Delavault, Alexei A. Kiselev, Martin Peng, Kersten S. Rabe, Julian S. Hertel, Marc F. Münker, Jennifer Kühne, Judith Felk, Lara Reuber, Adrian Neukirch
article en

Abstract

Carrier-free enzyme materials offer maximal catalytic density but are typically limited to monolithic or amorphous architectures with restricted process compatibility. Here, we introduce programmable carrier-free all-enzyme beads as structurally defined, porous biocatalytic particles for modular continuous-flow operation. The beads are generated via droplet-based self-assembly of complementary enzyme building blocks, followed by cryogenic consolidation, yielding mechanically robust and monodisperse protein particles that retain full catalytic competence after drying and rehydration. Using mechanistically distinct model systems, including cofactor-independent decarboxylation and metal-dependent C─C bond formation, we demonstrate stable long-term continuous-flow operation exceeding 80 h and compatibility with biphasic solvent systems at elevated substrate concentrations. Beyond single-enzyme catalysis, the bead architecture accommodates binary cofactor-regenerating assemblies, integrated ternary cascades with dual cofactor recycling, and modular combinations of distinct bead populations enabling sequential nucleotide phosphorylation. Notably, flow-induced restructuring leads to adaptive consolidation of packed beds, enhancing effective catalytic volume without compromising mass transport. By uniting structural programmability, high catalytic density, architectural modularity, and adaptive behavior under flow, carrier-free all-enzyme beads bridge molecular enzyme engineering and reactor design, expanding the materials toolbox for scalable and reconfigurable continuous biocatalysis.

Advanced Materials
Karlsruhe Institute of Technology (DE)
Openalex Percentile: Top 29%
Enzyme Catalysis and Immobilization
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