Alba Burbano, D. | bioRxiv Science

bioRxiv2026

Conjugation-based genome engineering enables rapid prototyping and bioproduction in non-model bacteria

Non-model bacteria offer unique metabolic capabilities for sustainable bioproduction, yet their limited genetic accessibility hinders systematic strain development. Here we present conjugation-based serine recombinase-assisted genome engineering (cSAGE), a portable platform for sequential, site-specific genomic integration in transformation-resistant bacteria. Using Rhodobacter sphaeroides as a testbed, we show that genome integration fails by electroporation and is not rescued by disruption of three candidate restriction endonucleases. Conjugative delivery of the same integration vectors recovers genomic integrants at frequencies of approximately 10-4 per recipient cell, an improvement of at least five orders of magnitude over electroporation. We demonstrate site-specific genomic integration across eight bacterial hosts spanning four classes and two phyla, as well as three sequential payload integrations using a standardized, non-replicating plasmid toolkit. We then use cSAGE to install the same bioproduction pathway in two Rhodopseudomonas palustris strains: the reference strain CGA009 and the environmental isolate P4, for which genetic engineering has not previously been reported. Under anoxygenic photosynthetic growth conditions, engineered P4 produces p -vinylphenol from p -coumarate, whereas CGA009 engineered with the same construct, does not. By enabling standardized genome engineering and cross-host evaluation of bioproduction pathways, cSAGE provides a general framework for non-model strain prototyping and biotransformation discovery.

synthetic biology↗

bioRxiv2024

Carbon-conserving Bioproduction of Malate in an E. coli-based Cell-Free System

Formate, a biologically accessible form of CO2, has attracted interest as a renewable feedstock for bioproduction. However, approaches are needed to investigate efficient routes for biological formate assimilation due to its toxicity and limited utilization by microorganisms. Cell-free systems hold promise due to their potential for efficient use of carbon and energy sources and compatibility with diverse feedstocks. However, bioproduction using purified cell-free systems is limited by costly enzyme purification, whereas lysate-based systems must overcome loss of flux to background reactions in the cell extract. Here, we engineer an E. coli-based system for an eight-enzyme pathway from DNA and incorporate strategies to regenerate cofactors and minimize loss of flux through background reactions. We produce the industrial di-acid malate from glycine, bicarbonate, and formate by engineering the carbon-conserving reductive TCA and formate assimilation pathways. We show that in situ regeneration of NADH drives metabolic flux towards malate, improving titer by 15-fold. Background reactions can also be reduced 6-fold by diluting the lysate following expression and introducing chemical inhibitors of competing reactions. Together, these results establish a carbon-conserving, lysate-based cell-free platform for malate production, producing 64 M malate after 8 hours. This system conserves 43% of carbon otherwise lost as CO2 and incorporates 0.13 mol CO2 equivalents/mol glycine fed. Finally, techno-economic analysis of cell-free malate production from formate revealed that the high cost of lysate is a key challenge to the economic feasibility of the process, even assuming efficient cofactor recycling. This work demonstrates the capabilities of cell-free expression systems for both the prototyping of carbon-conserving pathways and the sustainable bioproduction of platform chemicals. HighlightsO_LISuccessfully engineered the carbon-conserving reductive TCA and formate assimilation pathways in a lysate-based cell-free system for production of the C4 industrial di-acid malate from C1 and C2 feedstocks. C_LIO_LIAchieved a 6-fold reduction in competition from the endogenous cell-free metabolism by blocking TCA activity using small-molecule inhibitors and lysate dilution. C_LIO_LIIncreased accumulation of malate by 15-fold in a single-step reaction using cell-free expression of an enzymatic cofactor regeneration system. C_LIO_LITechno-economic analysis identified routes for economically feasible production of malate from renewable feedstocks in a cell-free system by improving conversion efficiency and reducing lysate cost. C_LI Graphical Abstract O_FIG O_LINKSMALLFIG WIDTH=200 HEIGHT=161 SRC="FIGDIR/small/623433v1_ufig1.gif" ALT="Figure 1"> View larger version (29K): org.highwire.dtl.DTLVardef@3c89adorg.highwire.dtl.DTLVardef@72d9b3org.highwire.dtl.DTLVardef@327e2eorg.highwire.dtl.DTLVardef@fa0964_HPS_FORMAT_FIGEXP M_FIG C_FIG

synthetic biology↗