<YOUR NAME HERE> — HTBAA Fall 2026
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See the nav bar on the left to look through my work for How To Biomanufacture Almost Anything (Fall 2026)!
See the nav bar on the left to look through my work for How To Biomanufacture Almost Anything (Fall 2026)!
A light-activated, sprayable protein coating that helps small-scale farmers reduce post-harvest fruit loss without needing cold-chain refrigeration. Post-harvest loss is a major bottleneck for smallholder farmers globally, who often lack access to refrigeration and lose large portions of their harvest to spoilage. I’m starting with bananas specifically India is the world’s largest banana producer, and bananas ripen rapidly in tropical conditions with the intent to extend the approach to other climacteric produce (mangoes, tomatoes, etc.) once the core mechanism is validated.
The vision: farmers rehydrate a shelf-stable powder sachet into a liquid protein solution, spray it onto freshly harvested bananas, then expose the crate to a brief flash of blue/UV-A light. The light triggers the coating to cure into a thin, gas-limiting barrier that slows respiration and ethylene-driven ripening a “farmer-controlled optical seal,” rather than relying on an automatic, hard-to-detect spoilage signal like ripening heat (which I originally considered, but it’s too weak and unreliable to distinguish from normal ambient temperature swings). To keep the sachet itself shelf-stable without expensive freeze-drying infrastructure, the formulation would also incorporate tardigrade-derived CAHS (desiccation- tolerance) proteins as a lower-cost way to stabilize the powder for storage and transport.
A cell-free protein synthesis (CFPS) platform, likely derived from an industrial E. coli strain, used to manufacture all protein components in a centralized facility rather than spraying any living, engineered organism directly onto food (avoiding a major food-safety/regulatory hurdle). The CFPS system would produce three distinct recombinant proteins:
All three proteins are recombinantly expressed via CFPS from engineered DNA templates none are extracted from actual silkworms or tardigrades.
The main engineering challenge is tuning the formulation so it cures reliably and quickly under low-energy light, without cracking during rough transit. I’d use a desktop liquid-handling robot (e.g. Opentrons) combined with programmable microfluidics to generate many small-scale formulations varying protein concentration, riboflavin ratio, and pH and test how each responds to different light wavelengths and intensities. Optical sensors could track how quickly each formulation transitions from liquid to solid, letting me map out which combination cures fast enough for real agricultural use. This Opentrons/microfluidics setup is a development and pilot-scale platform. At full agricultural volume, the same optimized formulation would move to larger-volume, parallelized bioreactors with automated purification and fill lines, rather than scaling by running more small-well reactions.
For a hypothetical 1,000 kg batch of bananas (~6,667 bananas at ~150g each), assuming roughly 15 mL of a 3% (w/v) protein spray per banana, that’s about 100 liters of spray, requiring roughly 3 kg of pure protein. Cell-free systems can currently yield roughly 1–2 g of protein per liter of lysate, so producing 3 kg would require on the order of 1,500–3,000 liters of lysate achievable with a couple of batch runs in a pilot-scale (~1,000 L) bioreactor over roughly 1–2 days. This 1–2 g/L figure reflects best-case, highly optimized published CFPS systems; typical reported yields are often lower (hundreds of mg/L), so this is an optimistic first-pass assumption rather than a conservative one. These numbers are rough, assumption-based estimates for a first pass, not measured or sourced values.
Notably, none of these existing solutions use a deliberate, user-triggered activation step they’re all passive once applied (self-assembly, humidity annealing, or diffusion). The farmer-controlled light trigger in my concept appears to be the most distinct part of this idea relative to what already exists.
I used Claude and OpenAI’s ChatGPT to help brainstorm, refine, and sanity-check this concept, including verifying which proposed mechanisms and citations were scientifically real versus overstated or fabricated. An earlier AI-generated draft included a citation (“Ahmad et al., 2020”) that could not be verified and was likely fabricated — it has been removed and replaced with verified sources above.
Note on Software: This DNA design was constructed, optimized and checked using Asimov Kernel (construct editor, coding-sequence optimization tool and construct checker). Protein and part identifiers come from public databases (UniProt, iGEM Registry) and are listed as accession numbers in the References section.
Some organisms survive almost complete water loss. Two protein families implicated in this are the tardigrade CAHS proteins and the nematode group 3 LEA proteins. My goal this week was to design DNA that could later be used to test whether two such proteins can be expressed in E. coli: CAHS3 from the tardigrade Ramazzottius varieornatus and AavLEA1 from the nematode Aphelenchus avenae.
I kept them as two separate constructs, not a fusion, so each protein can be tested on its own, and later in combination. Trehalose, a well-known desiccation protectant, is treated as an external variable and is not encoded in the DNA.
This page is a design study. Whether these proteins protect E. coli is a hypothesis for future testing, not a result of this homework.
Protein 1: CAHS3
| Name | CAHS3 (cytosolic-abundant heat-soluble protein 3) |
| Organism | Ramazzottius varieornatus (tardigrade) |
| UniProt | J7M3T1 |
| Length | 303 aa |
CAHS proteins are tardigrade-specific, intrinsically disordered proteins that are abundant in the cytosol and heat-soluble. CAHS3 is one of the most highly expressed CAHS paralogs in R. varieornatus. Work on tardigrade-specific disordered proteins reported that they can contribute to desiccation tolerance, including when expressed in heterologous systems (Boothby et al. 2017). I chose it because it is a natural candidate protectant that is small enough to express easily in bacteria.
Protein 2: AavLEA1
| Name | AavLEA1 (late embryogenesis abundant protein 1, group 3 LEA) |
| Organism | Aphelenchus avenae (nematode; UniProt lists Aphelenchoides avenae) |
| UniProt | Q95V77 |
| Length | 143 aa |
The A. avenae LEA gene is induced during dehydration (Browne et al. 2004), and the protein reduces aggregation of other proteins during drying and rehydration in vitro (Chakrabortee et al. 2007). I chose it as a second candidate with a different origin and, plausibly, a different mechanism, so the two can be compared instead of assuming all desiccation proteins act alike.
Each protein sequence was converted to a coding sequence (CDS). The reference CDS lengths, including a single stop codon, were:
| Protein | Amino acids | Reference CDS |
|---|---|---|
| CAHS3 | 303 | 912 bp |
| AavLEA1 | 143 | 432 bp |
(303 × 3 + 3 = 912 and 143 × 3 + 3 = 432, consistent with one stop codon each.)
Why optimize? The genetic code is degenerate: most amino acids are encoded by several synonymous codons, and organisms use them at different frequencies, matched to their tRNA pools. A gene from a tardigrade or a nematode uses codons that may be rare in E. coli, which can slow or stall translation. Re-encoding the same protein with codons E. coli prefers can improve expression (Gustafsson et al. 2004). It is not a guarantee, because synonymous changes also alter mRNA structure and translation kinetics and can affect folding (Mauro 2018), so I treat optimization as a design choice that still needs experimental testing.
Organism chosen: E. coli, specifically BL21(DE3), because it is the standard T7 expression host and the one most accessible for a first test.
Settings used in the Kernel Coding Sequence Optimization tool (both proteins):
| Parameter | Setting |
|---|---|
| Input | Protein amino-acid sequence |
| Target organism | E. coli |
| Algorithm | SIMPLE_0_3 |
| Stop codons | TGA and TAA |
| Signal peptide | No |
| CpG avoidance | No |
| Restriction-site / motif avoidance | None specified |
The original CDSs were kept unchanged and the optimized versions saved separately. Each optimized CDS ends with TGATAA (double stop), giving about 915 bp (CAHS3) and 435 bp (AavLEA1).
My first constructs used the original CDSs with the same parts. The Kernel construct checker returned 0 errors but 7 warnings for both:
I interpreted these one by one instead of silencing them all. Warnings 2 and 3 (Kozak/UTR/poly-A) are eukaryotic conventions that do not apply to a bacterial T7 → RBS → terminator cassette, so I did not add eukaryotic elements just to satisfy the checker. The stop-codon warning was a real sequence-level issue that optimization with TGA + TAA fixed. After rebuilding both constructs with the optimized CDSs, the checker reported 0 errors and 0 warnings for both.
Construct 1: CAHS3

SBOL-style schematic and linear map: T7 promoter, RBS_B0034, CAHS3_Ecoli_Optimization, Terminator_BBa_B0015.
Construct 2: AavLEA1

SBOL-style schematic and linear map: T7 promoter, RBS_B0034, AavLEA1_Ecoli_Optimization, Terminator_BBa_B0015.
| Part | Choice | Role |
|---|---|---|
| Promoter | T7 promoter | Transcription by T7 RNA polymerase in BL21(DE3) |
| RBS | BBa_B0034 | Bacterial translation initiation |
| CDS | CAHS3 or AavLEA1 (E. coli-optimized) | Candidate protective protein |
| Terminator | BBa_B0015 | Bacterial transcription termination |
| Construct | Errors | Warnings |
|---|---|---|
| CAHS3 (optimized) | 0 | 0 |
| AavLEA1 (optimized) | 0 | 0 |
A clean checker result means the constructs pass Kernel’s computational checks. It does not show that the proteins will express, fold, stay soluble, or protect cells.
A CAHS3–AavLEA1 fusion would raise extra questions about whether each partner keeps its behavior, and it would make it impossible to attribute an effect to one protein. Separate cassettes let me test each protein alone, and later co-express them, without redesigning the DNA. The simplicity is deliberate.
Trehalose is a small molecule protectant, and I did not add a biosynthesis pathway (e.g. OtsA/OtsB). Keeping it as an external condition keeps the genetic variable (which protein) separate from the formulation variable (trehalose or not). A possible future experimental layout (not performed):
| Condition | CAHS3 | AavLEA1 | Exogenous trehalose |
|---|---|---|---|
| Control | − | − | ± |
| CAHS3 | + | − | ± |
| AavLEA1 | − | + | ± |
| Both | + | + | ± |
Cell-dependent production. The cassette would be placed on a plasmid and transformed into E. coli BL21(DE3), which carries the gene for T7 RNA polymerase under inducible control. Inducing the host makes T7 polymerase, which recognizes the T7 promoter and transcribes the cassette into mRNA; transcription stops at BBa_B0015. A ribosome binds the BBa_B0034 RBS, finds the start codon, and translates codon by codon (each 3-nt codon specifies one amino acid, read by tRNAs) until it reaches the stop codon, releasing CAHS3 or AavLEA1.
Cell-free production. The same cassette, supplied as a linear gene fragment or plasmid, could be added to a cell-free expression system that contains T7 RNA polymerase, ribosomes, tRNAs and energy sources, avoiding transformation and growth.
Caveats. T7 expression can be leaky and impose a metabolic burden, so induction conditions would need optimization. BBa_B0015 is a general bacterial terminator, not a T7-specific one, so transcriptional read-through is possible. No purification tag was included in these designs, which would make purification harder without adding one later.
A single eukaryotic gene can code for several proteins at the transcriptional/RNA level mainly through alternative splicing (different exon combinations from one pre-mRNA), and also through alternative promoters or transcription start sites. My constructs are bacterial and single-gene, so this does not apply directly. I did not include a DNA/RNA/protein alignment here.
The expression cassettes are designed and annotated (see the maps above). The Twist ordering portion has not been completed at the time of writing: no vector has been selected and no order or quote has been made. When I do it, I plan to import the two annotated inserts as clonal genes and choose a Twist cloning vector with a resistance marker permitted at MIT/Harvard (ampicillin, chloramphenicol or kanamycin).
(i) What would I sequence and why? The final plasmids carrying the CAHS3 and AavLEA1 cassettes, to confirm that the physical DNA matches the design. The regions that matter most are the promoter–RBS junction, the RBS–CDS junction, the full CDS with its stop codons, and the CDS–terminator junction. A single point error in a CDS could change the protein.
(ii) Technology. I would use Sanger sequencing (first generation) with primers flanking the cassette, and consider Oxford Nanopore whole-plasmid sequencing (third generation) if I wanted the entire plasmid confirmed.
(i) What would I synthesize and why? The two optimized expression cassettes: T7 promoter → BBa_B0034 → CAHS3 (optimized) → BBa_B0015 and the same with AavLEA1. Optimized CDSs are designed sequences that do not exist as natural DNA, so they must be synthesized before the hypothesis can be tested.
(ii) Technology. Commercial gene synthesis (e.g. Twist Bioscience), ordering the cassettes as clonal genes in a cloning vector.
(i) What would I edit and why? If the proteins show promise, I would insert a cassette into a defined E. coli genomic site instead of keeping it on a plasmid, for stable inheritance and defined copy number. Plasmids are easier for early testing, so I would start with plasmids.
(ii) Technology. CRISPR-Cas9 combined with recombineering (λ-Red-mediated homologous recombination) in E. coli.
Completed: protein selection; two T7 expression cassettes with BBa_B0034 and BBa_B0015; E. coli codon optimization with double stop; identification and interpretation of checker warnings; final constructs with 0 errors and 0 warnings in Kernel.
Not performed: Twist order, DNA synthesis, transformation, expression, purification, desiccation or trehalose experiments, or genome integration.
Unknowns: whether either protein expresses and stays soluble in E. coli; whether codon optimization helps or hurts here; whether either protein provides measurable protection; and how trehalose interacts with them.
I used AI assistants (ChatGPT and Claude) to help learn the Kernel workflow, interpret checker warnings, organize this write-up and cross-check my reasoning and citations. Design decisions, settings and Kernel results documented here come from my own work in the tool, and the cited papers were used for the scientific claims.
K-glutamate and Mg-glutamate have different roles in cell-free protein synthesis.
K-glutamate mainly provides potassium ions and helps establish the ionic environment of the reaction. Potassium concentration affects ribosome function, enzyme activity, nucleic-acid interactions, and the overall physiological-like environment of the lysate.
Mg-glutamate provides magnesium ions. Magnesium is especially important because it interacts with ATP and other nucleotides and is required for proper ribosome structure and function. However, the free Mg²⁺ concentration is strongly affected by other negatively charged molecules in the reaction, including ATP, nucleic acids, and phosphate-containing compounds.
The two concentrations therefore cannot be treated independently. Changing Mg-glutamate can strongly affect translation because too little Mg²⁺ can reduce ribosome stability and activity, while too much can also inhibit protein synthesis. K-glutamate mainly tunes the ionic environment and has a broader acceptable range around the optimum.
In the optimization experiments of Jewett and Swartz (2004), both K-glutamate and Mg-glutamate affected protein synthesis, but the Mg-glutamate response was particularly important because magnesium directly interacts with nucleotides and the ribosome. Mg-glutamate is therefore generally the more sensitive component to optimize carefully, while K-glutamate is used to establish the appropriate overall ionic strength. This is also why CFPS formulations often keep Mg²⁺ in a relatively narrow range while adjusting K-glutamate over a broader range. The true optimum can also depend on the lysate batch and other components present.
The two systems regenerate the nucleotide triphosphates required for transcription and translation using different strategies.
PEP + NTP system: the reaction is supplied directly with ATP, GTP, CTP, and UTP, which are required for RNA synthesis (ATP also supports general energy metabolism). Phosphoenolpyruvate (PEP) acts as a high-energy phosphate donor, regenerating ATP from ADP so transcription and translation can continue. This is a straightforward, well-established approach that gives strong protein production, but PEP is relatively expensive, and phosphate byproducts can accumulate during the reaction, eventually inhibiting the system or shifting pH. Jewett and Swartz specifically identified the cost and accumulation of inhibitory phosphate as limitations of this strategy.
Ribose + NMP system: instead of supplying NTPs directly, the reaction supplies ribose plus nucleoside monophosphates (AMP, CMP, GMP, UMP). The lysate’s own metabolic enzymes regenerate the needed NTPs from these cheaper precursors. This can substantially reduce reagent cost, since NMPs and ribose are less expensive than purified NTPs. Olsen et al. (2026) demonstrated that CFPS can generate NTPs from nitrogenous bases and ribose, achieving high protein yields while substantially reducing reagent cost.
| PEP + NTP | Ribose + NMP |
|---|---|
| Directly supplies NTPs | Uses metabolism to regenerate NTPs |
| Uses PEP as energy donor | Uses ribose + lysate metabolism |
| Established, robust | More dependent on lysate metabolic activity |
| Higher reagent cost | Lower reagent cost |
| Can accumulate inhibitory phosphate | Reduces dependence on phosphorylated substrates |
In short: PEP + NTP is a strong conventional starting point; Ribose + NMP is attractive specifically for cost optimization and metabolic recycling. The best choice depends on the lysate, target protein, and the desired balance between yield and cost.
A representative PANOx-SP-family formulation contains approximately:
Jewett and Swartz developed this general Cytomim/PANOx family to provide a stable metabolic environment for CFPS. Later PANOx-SP formulations became a widely used high-performing reference system.
Olsen et al. developed a substantially more cost-optimized formulation by screening 58 reagent components across 1,231 different reaction combinations. Their final optimized formulation (RFopt) uses just 12 components — a major simplification compared to PANOx-SP — and moves away from expensive phosphorylated energy substrates.
Note on specific yield/cost figures: I was not able to independently verify an exact $/g or g/L figure for RFopt beyond the paper’s reported 84–99% cost reduction (averaging ~95%) compared to state-of-the-art phosphorylated-energy formulations. I’m citing that averaged figure here since I could confirm it, rather than a specific $/g number I could not verify — worth double-checking against the actual PDF in the course drive folder if an exact per-gram cost is needed.
The RFopt strategy uses components including higher K-glutamate, Mg-glutamate, amino acids, potassium phosphate, ribose, glucose, nicotinamide, and nucleoside monophosphates (AMP, CMP, GMP, UMP) — rather than the PEP + direct-NTP combination used in PANOx-SP.
| Feature | PANOx-SP | Olsen et al. RFopt |
|---|---|---|
| Energy strategy | PEP-based | Ribose / non-phosphorylated |
| Nucleotide strategy | Direct NTP addition | NMP + ribose metabolism |
| Number of components | Relatively high | Much lower (12 core components) |
| Main advantage | Established, robust reference system | Large, verified cost reduction (84–99%, avg. ~95%) |
| Main trade-off | Expensive reagents, phosphate buildup | More dependent on lysate metabolism |
The main difference is the energy and nucleotide regeneration strategy: PANOx-SP prioritizes a well-established, direct system with PEP and supplied NTPs, while RFopt prioritizes cost reduction and metabolic recycling, using cheaper precursors and fewer total components.
I used AI tools to help research and structure this comparison. One draft included specific yield and cost figures ($/g and g/L) for the Olsen et al. formulation that I could not independently verify when I checked — these have been replaced with the verified, citable cost-reduction range reported in the paper (84–99%, averaging ~95%).