Supporting Stem Cell Research with Accurate 3D Modelling

3dinfo2
2 days ago
4 min read

Supporting Research at the University of Calgary

Scaling stem cell production sounds straightforward. Increase the volume, keep everything else consistent, and expect the same outcome.

In practice, it rarely works that way.

At small laboratory volumes, many bioreactors perform well. Once those same processes move to clinically relevant sizes, growth can slow. Cell quality can shift. Results that once felt predictable become harder to reproduce.

Researchers at the University of Calgary wanted to understand why.

Their focus turned to fluid dynamics. More specifically, how the internal flow environment inside a bioreactor influences stem cell expansion at the 3 litre scale.

Rapid3D supported this work by generating accurate CAD models of one of the clinical-scale systems used in the study. Those models became the starting point for advanced fluid simulations.

This blog references the Engineering Conferences International presentation delivered February 4, 2026, along with materials shared by the University of Calgary and project collaborators.

The Real Question: Does Geometry Change Performance?

Inside any bioreactor, fluid is constantly moving. That movement determines:

How nutrients circulate
How aggregates form
How much shear stress cells experience

Stem cells are highly sensitive to these conditions.

The research team compared two different 3 litre systems:

A Vertical-Wheel bioreactor (PBS-3)
Generic Stirred Suspension System

Even if two systems hold the same volume, their internal shapes are different. That geometry changes how fluid behaves.

To properly evaluate those differences, the team used M-Star CFD, a time-accurate simulation platform that models real fluid motion inside complex geometries.

Accurate geometry was essential. That is where Rapid3D came in.

Capturing the Geometry Through 3D Scanning

Before digital modelling could begin, the physical geometry of the bioreactor vessels needed to be captured accurately. The internal shape of the vessel, including the wheel assembly and surrounding flow space, directly influences how fluid behaves during operation.

Rapid3D performed high-resolution 3D scanning of two bioreactor vessels using a Creaform HandySCAN BLACK Elite handheld 3D scanner. This system is designed for capturing precise geometry from complex physical objects and is commonly used in reverse engineering and inspection applications.

The scanning process captured the full external geometry of each vessel, producing detailed mesh data that represented the physical systems as they exist in the laboratory.

The resulting scan data provided the foundation for the CAD modelling work that followed.

Building the Digital Model

With the scan data captured, the next step was converting that geometry into usable CAD.

Rapid3D generated clean, detailed models of the University’s stirred suspension system. These models were then used directly in the simulation workflow.

This was not just about visual representation. The CAD defined the internal flow space. Any inaccuracies would directly impact simulation results.

By providing reliable digital geometry, we helped ensure the fluid modelling reflected the real system in operation.

What the Simulations Revealed

One of the first findings was simple but important. To achieve the same overall energy levels inside each system, the agitation speeds had to be drastically different.

Matching one performance metric did not mean the systems behaved the same internally. Particle simulations showed distinct mixing patterns between the two designs. The internal flow structures were not identical, even when bulk energy values were matched.

That difference became more meaningful when paired with biological testing.

Linking Flow to Cell Growth

Under controlled batch culture conditions, both systems produced similar growth results when energy levels were matched.

Under perfusion conditions, where media is continuously refreshed, differences became more apparent. One system showed reduced cell densities at later days of culture but aggregate structure was maintained in both systems.

Although the results of this head to head comparison showed comparable growth and aggregate structure, the next question was do the small-scale models result in the same outputs at the larger scale? This is important as small-scale models are needed for rapid and cost-effective testing but need to be reliable models before going into clinical manufacturing. The Vertical-Wheel showed strong linear scalability meaning the results from the small laboratory scale (0.1L) matched the results in the clinical scale (3L). Traditional stirred platforms did not scale as consistently.

The takeaway is straightforward. Geometry matters more than volume alone.

Why This Matters

Scaling advanced therapies from research to clinical production is one of the biggest challenges in regenerative medicine.

This study reinforces a core engineering principle.

Small differences in internal design can create meaningful changes in performance. Accurate CAD models allow researchers to understand, simulate, and refine those systems before making costly changes in hardware or process conditions.

By supporting the University of Calgary with precise digital geometry, Rapid3D contributed to research aimed at improving the predictability of clinical-scale stem cell manufacturing.

Looking Ahead