Researchers Developed New 3D-Printed Bioreactor

Scientists created a solid-state device that converts methane waste into chemicals at higher efficiencies.

Updated on Sept. 28, 2026 in Life Sciences

A close-up of an intricate, porous 3D-printed white lattice structure used for chemical conversion in a laboratory setting. — Researchers at Lawrence Livermore National Laboratory have developed a 3D-printed solid-state bioreactor that converts methane waste into succinate ten times more efficiently than traditional systems. AI Illustration. Upload story photo >

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Researchers at the Lawrence Livermore National Laboratory have developed a 3D-printed solid-state bioreactor capable of converting methane waste into succinate. The device outperforms conventional liquid-phase systems by over 10 times by using methanotrophs housed in hydrogel-encased 3D scaffolds.

Why it matters

Conventional liquid-phase bioreactors struggle with slow mass transfer when processing poorly soluble gases like methane. This new design offers a potential path for cost-effective methane conversion at small-scale waste facilities.

The bioreactor utilizes additive manufacturing to integrate scaffolds with hydrogel-encased microorganisms, which process methane without added heat or pressure. Performance testing confirms the device is over 10 times more efficient than traditional systems.

The players

Lawrence Livermore National Laboratory

This facility is a premier research institution that focuses on science and technology in support of national security.

University of North Texas

This public research university served as a collaborating institution for the bioreactor development project.

The details

Gas flows through a porous, 3D-printed scaffold that allows direct interaction between methane and the bacteria trapped in the hydrogel. This structure overcomes the efficiency limitations found in standard bioreactors, which often fail to effectively process gases with low solubility.

The research findings were published in September 2026.

The Big Picture

This development follows the precedent set by the Lawrence Livermore National Laboratory methane bioconversion research project. It represents a theoretical shift toward solid-state processing, moving away from liquid-phase limitations that have long hindered the viability of small-scale methane mitigation.

The technology could eventually lead to more efficient waste-to-chemical conversion, potentially lowering costs for small-scale methane processing facilities. Further research is currently underway to adapt this solid-state bioreactor concept to other industrial bioprocesses.

The takeaway

This innovation demonstrates how 3D-printed structures can bypass traditional physical limitations in biochemical processing. Future deployment of this technology could provide an effective tool for managing methane emissions at smaller industrial sites.