The present invention relates to nanostructured ceramic films and, more specifically, to a nano-structured ceramic film with controlled pore size providing a chemically, optically and mechanically robust substrate for high-throughput solid state manufacturing of synthetic oligonucleotides.
DNA synthesis occurs in all eukaryotes and prokaryotes. The molecular in vivo machinery involved in DNA synthesis has been studied extensively since the 1950's. The accurate synthesis of DNA is important in order to avoid mutations to DNA which could lead to diseases such as cancer. DNA biosynthesis in nature occurs via the polymerase chain reaction. In vivo DNA polymerases are highly accurate, with an intrinsic error rate of less than one mistake for every 10 million nucleotides added. In addition, some DNA polymerases also have proofreading ability; they can remove nucleotides from the end of a growing strand in order to correct mismatched bases.
Extracellular (in vitro) DNA amplification or gene synthesis—physically creating artificial gene sequences using the polymerase chain reaction and other enzymes in solution, is slow and prone to errors. Furthermore, for these to function a DNA template must first be constructed by other means. Purely chemical means to create DNA are now available that could one day have the potential to supersede in length and accuracy the in vitro biosynthesis methods without the need for a pre-existing template.
Fully synthetic oligonucleotides are critical in nearly all disciplines of modern biology and precision medicine. Synthetic Biology, cell-free DNA (cfDNA) diagnostics, mRNA vaccines, interference RNA cancer therapeutics, DNA Banking rely completely on the ability to generate error free oligonucleotide templates. Such revolution in biology has created a large demand for high-quality oligonucleotides, resulting in many companies developing novel approaches to improve DNA synthesis on solid substrates using Phosphoramidite chemistry. Controlled pore glass (CPG) columns lacks the quality necessary to create long sequences. Oligos produced from silicon chips are 2-4 orders of magnitude cheaper than column based CPG oligos, with costs ranging from $0.00001-0.001 per nucleotide, depending on length, scale and platform. This is due in great part to the broad particle size distribution which leads to incomplete synthesis of oligonucleotides trapped in small spaces (“shortmers”). In addition, CPG columns are too large and difficult to scale for the hundreds if not thousands of sequences needed to generate a full gene.
Silicon chips arrays have been developed to automate the accurate synthesis of thousands of oligonucleotides for gene assembly. One step coupling efficiencies of silicon chips have reached values on the order of 98.5% which makes them commercially feasible, however yields remain low. Because the amount of surface area for reactions on silicon chips have physical limitations yield of these chips is very low. Increasing the surface area with nano-lithography is possible but extremely expensive. Thus, a new solid substrate offering CPG class yields and the higher quality and automation capabilities of silicon chips is highly needed to make the promise of synthetic biology a reality.
This is a key bottleneck for high-throughput and inexpensive synthetic gene and genome construction. Solutions are needed with narrower pore size distributions as well as new formats beyond columns with a potential for miniaturization (chips), a necessary step for automation of large oligonucleotide synthesis. Here, we provide an nano-structured aluminum oxide ceramics film which when formed into bio-chips it provides a suitable solid state high-throughput substrate for oligonucleotide synthesis.
Any new substrate that intends to replace controlled pore glass (CPG) or silicon for oligonucleotide synthesis has to offer significant advantages, such as higher yields and better quality. It should also minimize the need for adjustments to existing DNA synthesis processes and standard operating procedures. It should also be chemically stable to solvents and reagents use in oligonucleotide synthesis. Finally, it should also offer optical and mechanical properties suitable for automation procedures such as split and pool, QR code optical micro-printing, and be offered in various sizes down to a few millimeters, or even micrometers, with stable crack free edges. Materials with these qualities cannot be made with inexpensive polymers which tend to swell in the presence of solvents. Most semiconductor materials require expensive nano-lithography to add sufficient surface area for high loading. This is a tall order since pricing should not exceed the costs of current nano-patterned silicon wafers. Accordingly, there is a need in the art for an improved substrate for oligonucleotide synthesis that can address these concerns.
The present invention comprises a nano-structured ceramic film suitable for the synthesis of oligonucleotides (DNA and RNA). The film can be cut into chips of various sizes, from a few centimeters to a few hundred microns without edge cracking. The surface of the film sufficiently optically uniform for code micro-printing commonly used in optical recognition by automated DNA synthesizers, such as in split and pool operations. The chips are easily activated under very mild conditions and silanization, the first step in chemically drafting an oligonucleotide, proceeds uniformly on a mono-layer, sufficiently thin to allow reagents to flow unhindered through its pores. Mono layer silanization, such as with APTES silane coupling agent, for addition of universal linkers have been demonstrated and when compared to CPG and silicon chips appear yields appear quite favorable.
Chips according to the present invention offered increased surface area over silicon (150× or higher) and extremely narrow pore size distribution (compared to CPG), with ease of activation, silanization and cleavage. Extensive chemical testing shows the chips are stable under solvents and reagents used in the most common Phosphoramidite oligonucleotide synthesis. The chips show significant higher oligonucleotide loadings than silicon chips which is the current standard for large scale DNA automation. These attributes provide a potential new material for the next generation of oligonucleotide chemistries with improve pore diffusion, eliminating ‘shortmers’, increasing the size of ‘error-free’ oligonucleotides when compared with CPG and increasing yields when compared to silicon chips. The ceramic films are manufactured without the use of heavy metals, such as mercury and chrome, commonly used in the manufactured of nano-porous ceramics. These characteristics bring these materials into the realm of potential cost-effective replacements for existing CPG columns and silicon chips for oligonucleotide synthesis automation.
The present invention will be more fully understood and appreciated by reading the following Detailed Description in conjunction with the accompanying drawings, in which:
Referring to the drawings, wherein like numerals refer to like parts throughout, the present invention comprises a nano-structure ceramic material that can be used for the synthesis of long oligonucleotides. A ceramic film according to the present invention provides CPG class like loading with a much narrower pore size distribution, easier activation, and with optimal mechanical and optical properties comparable to silicon chips for oligonucleotide chemistry. In addition, the ceramic film of the present invention is highly stable in the most common solvents and reagents used in Phosphoramidite and related chemistries. Nano-structured aluminum oxide ceramics according to the present invention offer better controlled pore size distributions than conventional materials such as CPG, and are simpler to activate with a large reactive surface as compared to silicon chips. The present invention includes data that supports the robust nature of nano-structured aluminum oxide ceramics for carrying out Phosphoramidite chemistry, with minimal to no degradation under common solvents and reagents used for oligonucleotide synthesis. In addition, chips for high-throughput solid state oligonucleotide synthesis were manufactured and tested. Further properties were optimized for DNA automation, including optical quality suitable for character micro-printing and recognition. Metal/ceramic composites for mechanical strength were prepared for use in multiple split and pool operations where high sheer in solution and mechanical sorting can cause physical damage to an unsupported ceramic substrate.
Ceramic films according to the present invention are made through standard wet chemistry procedures without the use of heavy metals and without the need for costly nano-lithography. Due to its regular nano-pore structure, the ceramic film offers over a one hundred fold surface area for loading compared to plain or nano-structured silicon chips, while the pores are sufficiently wide to allow sufficient diffusion for synthesizing oligonucleotides above 300 bases long. For example, one embodiment of the present invention has a pore spacing that is regular, around 82 nm, with a pore diameter of about 60 nm. Thus, there are around 133 pores per square micron. However, these dimensions can be varied during fabrication to optimize specific oligonucleotide synthesis requirements of length and quality. The present invention can also be prepared as a composite of two ceramic films flanking a metal core to provide a mechanical strength that ceramic films alone lack. Throughout the present application, the nano-structured ceramic material of the present invention is referred to DNAReax for simplicity.
The ceramic films of the present invention employ the improved properties of anodic aluminum oxide, a class of nano-porous ceramic substrates that can be made in large scale and in good quality.
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Stability of DNAReax on Oligonucleotide Solvents and Reagent Exposure
The surface area of DNAReax can be as high as 150 to 400 fold, depending on thickness and pore size, compared to a piece of non-porous silicon film of the same planar dimensions. More surface area means higher reactivity, more sites to react or be dissolved. Therefore, quantitative data of the stability of DNAReax in the presence of solvents and chemicals used in Phosphoramidite chemistry was experimentally obtained using the following protocol.
A sample of DNAReax consisting of a square coupon 75 micron in thickness measuring approximately 2 cm×2 cm and weighing ca. 70 mg was weighed in a high precision balance (+/−10 mg). Before weighing the sample was oven dried for 1 hour at 102° C. and allowed to cool to room temperature.
Four samples were positioned in an hourglass and labeled by exposure time from 20, 40, 60 and 120 minutes. This is comparable to the exposure times for a 100 nt oligonucleotide synthesis procedure where each base addition cycle lasts from 30 to 60 seconds.
Each reagent was poured with a plastic disposable pipet inside a well-ventilated hood. Additional reagent was added as needed to keep the sample immersed, due to solvent evaporation.
After each exposure time the sample is lifted out of the hourglass and rinsed thoroughly with dehydrated ethanol followed by copious DI water.
After 1 min the sample is transferred to a non-fibrous paper to absorb excess water before transferring to a clean piece of roughened aluminum foil to avoid close contact with glass or the oven surface to avoid transfer of any material to the tested coupon.
Samples were dried in the oven for 1 hour at 102° C., subsequently cooled and weighed in a high precision microbalance, labeled and stored.
Because this was a static (no flow) test, the data in some cases may show a small (<2%) weight gain (precipitation) but generally a small loss (dissolution). When high humidity is present, the main dissolution product is aluminum hydroxide. Aluminum hydroxide eventually precipitates out as it is highly insoluble and may add weight to the sample. For specific cases, a 12 hour exposure was undertaken to test the limits of stability.
Because aluminum oxide is sensitive to dissolution at high pH, a test was designed to test a strong base with small amounts of water. To furnish a functional oligonucleotide, all the protecting groups have to be removed. The N-acyl base protection and the 2-cyanoethyl phosphate protection are often removed simultaneously by treatment with inorganic bases or secondary or tertiary amines. Because water is often difficult to remove, its presence could alter the nature of the surface of aluminum oxide. Using an excess (10%) amount of water in the presence of two strong amines shows that DNAReax does not degrade over times significantly longer and at higher water content than required for deprotection.
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The list of reagents used in oligonucleotide chemistry is extensive. Furthermore, these are used often as mixtures. A representative list of reagents was chosen in close consultation with several research companies specialized in providing services to the oligonucleotide synthesis industry. The reagents are involved in all key steps of oligonucleotide chemistry. All reagents were purchased from Millipore Sigma Aldrich except for 3% dichloroacetic acid in dichloromethane, which was purchased from Glenn Research.
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Surface Modification for Oligonucleotide Synthesis
Prior to the start of the oligonucleotide synthesis, the solid support needs to be prepared with an organic compound that enables covalent attachment of a Universal Linker. A Universal Linker (UnyLinker) molecule is typically a chemically stable bridge carrying a conventional 4,4′-dimethoxytrityl (DMT) and succinyl groups to carry out oligonucleotide synthesis efficiently and smoothly. The organic compound is typically a silane coupling agent such as (3-Aminopropyl) triethoxysilane (APTES) or (3-Aminopropyl) trimethoxysilane (APTMS) that reacts with the metal oxide on one end and provides amino functionality to couple to the Universal Linker at the other end.
Activation
Prior to reacting the oxide surface with the silane coupling agent, the surface needs to be ‘activated’, i.e., the oxide surface groups transformed to hydroxide. For glass and silicon chips this usually requires strong acids such as nitric acid or even Piranha solutions. High temperatures are needed to hydroxylate the surface. DNAReax can be easily activated in 30% hydrogen peroxide at boiling temperatures (approximately 85° C.) for 15 minutes. After rinsing with sufficient ultra-pure water to eliminate any excess hydrogen peroxide DNAReax is dried for 2 hours at 102° C. in a convection oven and allowed to cool prior to applying the silane coupling agent.
Silanization: addition of a silane coupling agent, such as APTES, follows the typical published procedure used for silanization of CPG or silicon chips.
Results
The following protocol was used to check the uniformity of surface coverages with APTES.
Reagents:
Avidin (100 ug/mL in 1×PBS)
Phosphate Buffer Sulphate, PBS
Biotinylated-Fluorescein 50 uM
After APTES modification, various chips of DNAReax were processed as follows.
Derivatization with Avidin: DNAReax chips were incubated in sufficient avidin solution of 400 ul (100 ug/mL concentration in 1×PBS) for 2-3 hours at 37° C. in the dark, labeled and stored at 4° C. and covered with aluminum foil to protect them from light. DNAReax now contains immobilized avidin, chemically grafted with APTES. Avidin was chosen as a surrogate for a Universal Linker as it can be further imaged using a biotinylated fluorescent dye.
Confirmation of Silanization and derivatization with biotinylated fluorescein: this procedure verifies the APTES uniform effective coverage. Biotinylated fluorescein forms a strong non-covalent bond with Avidin in a 4:1 ratio
Prepare a known concentration of Fluorescence-4-biotin dye solution.
Recommended concentration is 50 mM.
Pour Fluorescence-4-biotin dye solution onto avidinated DNAReax with a pipet
Incubate for 2-4 hours at room temperature or overnight at 4° C. (covered with aluminum foil, protected from light).
Wash thoroughly 3 times with using TBS buffer pH=7.5 in sufficient amounts to rinse well all surfaces to eliminate any non-covalently bound fluorescein dye.
Quantification: to confirm the amount of fluorescein an Spectrofluorometer FS5 the full spectral signal (emission) was recorded for fluorescein, using 250 to 500 nm excitations. Note the high emission at 520 nm indicating the presence of fluorescein in
Monolayer Coverage: For porous media such as DNAReax a simple method to verify that pores are not clogged with APTES, or any other modification, can be done with a water drop break through time test. A piece of APTES modified DNAReax was placed on a flat dark surface, such as the surface of a lab benchtop. A 50 microliter drop of ultra-pure water is placed on the surface and the time measured for the water to penetrate the ceramic chip and appear on the dark surface without reaching the edges, as in
Uniformity of Silanization:
Uniformity of Coverage: fluorescent microscopy was used to verify the uniformity of coverage of the chip surface with a derivatized APTES surface. The results are compared to in
An Operetta CLS high-content analysis system with variable speed, sensitivity and resolution, fully-automated high-capacity, was used to image the surfaces. Sensitive sCMOS camera provided a large field of view and high resolution image capture. The Operetta's Harmony software was used to compare and contrast with similar procedure on 96-microwell with glass bottoms over a square grid.
Example 1: DNAReax samples are labeled: A1, A4, A5, B3, B4, B5, B6, C1 and C2. Illumination adjusted to the maximum 520 nm emission on the brightest (DNAReax) samples. Darker samples, A2, A3, A6, show incomplete or non-uniform APTES accumulation on SCHOTT and sodium glass samples, Bland B2, as evidence by the presence of bright spots (islands of fluorescein emission) over a mostly dark background.
Load Estimates
Three independent laboratories provided data to compare the oligonucleotide loadings on DNAReax with CPG and/or silicon chips
A major oligonucleotide independent laboratory provided loadings on DNAReax and compared them to CPG. Loadings of 200 nanomoles where achieved on a circular ceramic chip 20 mm in diameter. On a volume basis this is comparable to CPG but on a weight basis (DNAReax is 1.89 g/cc compared with CPG 0.4 g/cc) this is around 20% loading by weight.
A DNA synthesis laboratory conducted tests on columns packed with DNA chips. Two batches having two columns each were tested. The loads varied between 15.8 to 21.9 nanomoles/cm2 of DNAReax chip surface. On a weight basis this represents around 15% of the expected loads for their internal CPG column standards on a weight basis. Compared with state-of-the-art chip yields however this represent between 300% to 400% higher yields.
A different independent laboratory was asked to compare oligonucleotide loads on DNAReax with silicon chips used by the industry. An oligonucleotide with 30 bases was synthesized on DNAReax chips. Two separate batches of three chips each were tested. On average these batches gave yields between 4.9 and 8.3 nanomoles/cm2. These loads are 70 times higher than on silicon chips.
The present application claims priority to U.S. Provisional Application No. 63/183,723 filed on May 4, 2021.
Number | Date | Country | |
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63183723 | May 2021 | US |