Investigation of the dynamic behavior and filtration characteristics of membrane filter modules used in an extracellular vesicle bulk isolation device for therapeutic and cosmetic applications

This study addresses the key challenges associated with the efficient isolation of extracellular vesicles (EVs) from various biofluid samples for therapeutic and cosmetic applications. To this end, it investigates the internal dynamics and filtration characteristics of membrane filtration modules (MFMs), employing a rigorous methodology that combines computational fluid dynamics (CFD) simulations and modal analysis. The dynamic behavior of MFMs under operational constraints is analyzed, with a particular focus on pressure distribution and shear forces acting on the vesicles. With promising implications for regenerative medicine, drug delivery, and skin care, the study also investigates design optimizations to improve EV recovery, reduce vesicle damage, and facilitate affordable large-scale production. The crucial equilibrium between membrane pore size and the viscosity of the biofluid is a significant discovery. Larger pores (30 µm) paired with low-viscosity samples (1.15 mPa.s) reduce transmembrane pressure (TMP), lower flow resistance, and increase permeate velocity, thereby improving filtration efficiency and potentially enabling cost-effective large-scale production. Smaller pores (0.20 µm) on the other end improve selectivity but increase total pressure drop (TMP), especially with high viscosity biofluids (2.55 mPa.s), which can reduce throughput and increase fouling risks. The validated CFD model highlights how clean membrane resistance and concentration polarization affect long-term performance. It was found that, under ideal conditions, EV recovery rates for low-viscosity samples could reach 92%, while for higher-viscosity samples, they could reach 85%. These findings provide a deeper understanding of EV isolation and provide the practical design and operational guidelines needed to improve the scalability, energy efficiency, and yield of EV isolation systems.