A new platform for developing advanced metals at scale

Companies building next-generation products and breakthrough technologies are often limited by the physical constraints of traditional materials. In aerospace, defense, energy, and industrial tooling, pushing those constraints introduces possible failure points into the system, but companies don’t have better options, given that producing new materials at scale involves multiyear timelines and huge expenses.

Foundation Alloy wants to break the mold. The company, founded by a team from MIT, is capable of producing a new class of ultra-high-performance metal alloys using a novel production process that doesn’t rely on melting raw materials. The company’s solid-state metallurgy technology, which simplifies development and manufacturing of next-generation alloys, was developed over many years of research by former MIT professor Chris Schuh and collaborators.

“This is an entirely new approach to making metals,” says CEO Jake Guglin MBA ’19, who co-founded Foundation Alloy with Schuh, Jasper Lienhard ’15, PhD ’22, and Tim Rupert PhD ’11. “It gives us a broad set of rules on the materials engineering side that allows us to design a lot of different compositions with previously unattainable properties. We use that to make products that work better for advanced industrial applications.”

Foundation Alloy says its metal alloys can be made twice as strong as traditional metals, with 10 times faster product development, allowing companies to test, iterate, and deploy new metals into products in months instead of years.

The company is already designing metals and shipping demonstration parts to companies manufacturing components for things like planes, bikes, and cars. It’s also making test parts for partners in industries with longer development cycles, such as defense and aerospace.

Moving forward, the company believes its approach enables companies to build higher-performing, more reliable systems, from rockets to cars, nuclear fusion reactors, and artificial intelligence chips.

“For advanced systems like rocket and jet engines, if you can run them hotter, you can get more efficient use of fuel and a more powerful system,” Guglin says. “The limiting factor is whether or not you have structural integrity at those higher temperatures, and that is fundamentally a materials problem. Right now, we’re also doing a lot of work in advanced manufacturing and tooling, which is the unsexy but super critical backbone of the industrial world, where being able to push properties up without multiplying costs can unlock efficiencies in operations, performance, and capacity, all in a way that’s only possible with different materials.”

From MIT to the world

Schuh joined MIT’s faculty in 2002 to study the processing, structure, and properties of metal and other materials. He was named head of the Department of Materials Science and Engineering in 2011 before becoming dean of engineering at Northwestern University in 2023, after more than 20 years at MIT.

“Chris wanted to look at metals from different perspectives and make things more economically efficient and higher performance than what’s possible with traditional processes,” Guglin says. “It wasn’t just for academic papers — it was about making new methods that would be valuable for the industrial world.”

Rupert and Lienhard conducted their PhDs in Schuh’s lab, and Rupert invented complementary technologies to the solid-state processes developed by Schuh and his collaborators as a professor at the University of California at Irvine.

Guglin came to MIT’s Sloan School of Management in 2017 eager to work with high-impact technologies.

“I wanted to go somewhere where I could find the types of fundamental technological breakthroughs that create asymmetric value — the types of things where if they didn’t happen here, they weren’t going to happen anywhere else,” Guglin recalls.

In one of his classes, a PhD student in Schuh’s lab practiced his thesis defense by describing his research on a new way to create metal alloys.

“I didn’t understand any of it — I have a philosophy background,” Guglin says. “But I heard ‘stronger metals’ and I saw the potential of this incredible platform Chris’ lab was working on, and it tied into exactly why I wanted to come to MIT.”

Guglin connected with Schuh, and the pair stayed in touch over the next several years as Guglin graduated and went to work for aerospace companies SpaceX and Blue Origin, where he saw firsthand the problems being caused by the metal parts supply chain.

In 2022, the pair finally decided to launch a company, adding Rupert and Lienhard and licensing technology from MIT and UC Irvine.

The founders’ first challenge was scaling up the technology.

“There’s a lot of process engineering to go from doing something once at 5 grams to doing it 100 times a week at 100 kilograms per batch,” Guglin says.

Today, Foundation Alloys starts with its customers’ material requirements and decides on a precise mixture of the powdered raw materials that every metal starts out as. From there, it uses a specialized industrial mixer — Guglin calls it an industrial KitchenAid blender — to create a metal powder that is homogenous down to the atomic level.

“In our process, from raw material all the way through to the final part, we never melt the metal,” Guglin says. “That is uncommon if not unknown in traditional metal manufacturing.

From there, the company’s material can be solidified using traditional methods like metal injection molding, pressing, or 3D printing. The final step is sintering in a furnace.

“We also do a lot of work around how the metal reacts in the sintering furnace,” Guglin says. “Our materials are specifically designed to sinter at relatively low temperatures, relatively quickly, and all the way to full density.”

The advanced sintering process uses an order of magnitude less heat, saving on costs while allowing the company to forego secondary processes for quality control. It also gives Foundation Alloy more control over the microstructure of the final parts.

“That’s where we get a lot of our performance boost from,” Guglin says. “And by not needing those secondary processing steps, we’re saving days if not weeks in addition to the costs and energy savings.”

A foundation for industry

Foundation Alloy is currently piloting their metals across the industrial base and has also received grants to develop parts for critical components of nuclear fusion reactors.

“The name Foundation Alloy in a lot of ways came from wanting to be the foundation for the next generation of industry,” Guglin says.

Unlike in traditional metals manufacturing, where new alloys require huge investments to scale, Guglin says the company’s process for developing new alloys is nearly the same as its production processes, allowing it to scale new materials production far more quickly.

“At the core of our approach is looking at problems like material scientists with a new technology,” Guglin says. “We’re not beholden to the idea that this type of steel must solve this type of problem. We try to understand why that steel is failing and then use our technology to solve the problem in a way that produces not a 10 percent improvement, but a two- or five-times improvement in terms of performance.”

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Confronting the AI/energy conundrum

The explosive growth of AI-powered computing centers is creating an unprecedented surge in electricity demand that threatens to overwhelm power grids and derail climate goals. At the same time, artificial intelligence technologies could revolutionize energy systems, accelerating the transition to clean power.

“We’re at a cusp of potentially gigantic change throughout the economy,” said William H. Green, director of the MIT Energy Initiative (MITEI) and Hoyt C. Hottel Professor in the MIT Department of Chemical Engineering, at MITEI’s Spring Symposium, “AI and energy: Peril and promise,” held on May 13. The event brought together experts from industry, academia, and government to explore solutions to what Green described as both “local problems with electric supply and meeting our clean energy targets” while seeking to “reap the benefits of AI without some of the harms.” The challenge of data center energy demand and potential benefits of AI to the energy transition is a research priority for MITEI.

AI’s startling energy demands

From the start, the symposium highlighted sobering statistics about AI’s appetite for electricity. After decades of flat electricity demand in the United States, computing centers now consume approximately 4 percent of the nation's electricity. Although there is great uncertainty, some projections suggest this demand could rise to 12-15 percent by 2030, largely driven by artificial intelligence applications.

Vijay Gadepally, senior scientist at MIT’s Lincoln Laboratory, emphasized the scale of AI’s consumption. “The power required for sustaining some of these large models is doubling almost every three months,” he noted. “A single ChatGPT conversation uses as much electricity as charging your phone, and generating an image consumes about a bottle of water for cooling.”

Facilities requiring 50 to 100 megawatts of power are emerging rapidly across the United States and globally, driven both by casual and institutional research needs relying on large language programs such as ChatGPT and Gemini. Gadepally cited congressional testimony by Sam Altman, CEO of OpenAI, highlighting how fundamental this relationship has become: “The cost of intelligence, the cost of AI, will converge to the cost of energy.”

“The energy demands of AI are a significant challenge, but we also have an opportunity to harness these vast computational capabilities to contribute to climate change solutions,” said Evelyn Wang, MIT vice president for energy and climate and the former director at the Advanced Research Projects Agency-Energy (ARPA-E) at the U.S. Department of Energy.

Wang also noted that innovations developed for AI and data centers — such as efficiency, cooling technologies, and clean-power solutions — could have broad applications beyond computing facilities themselves.

Strategies for clean energy solutions

The symposium explored multiple pathways to address the AI-energy challenge. Some panelists presented models suggesting that while artificial intelligence may increase emissions in the short term, its optimization capabilities could enable substantial emissions reductions after 2030 through more efficient power systems and accelerated clean technology development.

Research shows regional variations in the cost of powering computing centers with clean electricity, according to Emre Gençer, co-founder and CEO of Sesame Sustainability and former MITEI principal research scientist. Gençer’s analysis revealed that the central United States offers considerably lower costs due to complementary solar and wind resources. However, achieving zero-emission power would require massive battery deployments — five to 10 times more than moderate carbon scenarios — driving costs two to three times higher.

“If we want to do zero emissions with reliable power, we need technologies other than renewables and batteries, which will be too expensive,” Gençer said. He pointed to “long-duration storage technologies, small modular reactors, geothermal, or hybrid approaches” as necessary complements.

Because of data center energy demand, there is renewed interest in nuclear power, noted Kathryn Biegel, manager of R&D and corporate strategy at Constellation Energy, adding that her company is restarting the reactor at the former Three Mile Island site, now called the “Crane Clean Energy Center,” to meet this demand. “The data center space has become a major, major priority for Constellation,” she said, emphasizing how their needs for both reliability and carbon-free electricity are reshaping the power industry.

Can AI accelerate the energy transition?

Artificial intelligence could dramatically improve power systems, according to Priya Donti, assistant professor and the Silverman Family Career Development Professor in MIT's Department of Electrical Engineering and Computer Science and the Laboratory for Information and Decision Systems. She showcased how AI can accelerate power grid optimization by embedding physics-based constraints into neural networks, potentially solving complex power flow problems at “10 times, or even greater, speed compared to your traditional models.”

AI is already reducing carbon emissions, according to examples shared by Antonia Gawel, global director of sustainability and partnerships at Google. Google Maps’ fuel-efficient routing feature has “helped to prevent more than 2.9 million metric tons of GHG [greenhouse gas] emissions reductions since launch, which is the equivalent of taking 650,000 fuel-based cars off the road for a year," she said. Another Google research project uses artificial intelligence to help pilots avoid creating contrails, which represent about 1 percent of global warming impact.

AI’s potential to speed materials discovery for power applications was highlighted by Rafael Gómez-Bombarelli, the Paul M. Cook Career Development Associate Professor in the MIT Department of Materials Science and Engineering. “AI-supervised models can be trained to go from structure to property,” he noted, enabling the development of materials crucial for both computing and efficiency.

Securing growth with sustainability

Throughout the symposium, participants grappled with balancing rapid AI deployment against environmental impacts. While AI training receives most attention, Dustin Demetriou, senior technical staff member in sustainability and data center innovation at IBM, quoted a World Economic Forum article that suggested that “80 percent of the environmental footprint is estimated to be due to inferencing.” Demetriou emphasized the need for efficiency across all artificial intelligence applications.

Jevons’ paradox, where “efficiency gains tend to increase overall resource consumption rather than decrease it” is another factor to consider, cautioned Emma Strubell, the Raj Reddy Assistant Professor in the Language Technologies Institute in the School of Computer Science at Carnegie Mellon University. Strubell advocated for viewing computing center electricity as a limited resource requiring thoughtful allocation across different applications.

Several presenters discussed novel approaches for integrating renewable sources with existing grid infrastructure, including potential hybrid solutions that combine clean installations with existing natural gas plants that have valuable grid connections already in place. These approaches could provide substantial clean capacity across the United States at reasonable costs while minimizing reliability impacts.

Navigating the AI-energy paradox

The symposium highlighted MIT’s central role in developing solutions to the AI-electricity challenge.

Green spoke of a new MITEI program on computing centers, power, and computation that will operate alongside the comprehensive spread of MIT Climate Project research. “We’re going to try to tackle a very complicated problem all the way from the power sources through the actual algorithms that deliver value to the customers — in a way that’s going to be acceptable to all the stakeholders and really meet all the needs,” Green said.

Participants in the symposium were polled about priorities for MIT’s research by Randall Field, MITEI director of research. The real-time results ranked “data center and grid integration issues” as the top priority, followed by “AI for accelerated discovery of advanced materials for energy.”

In addition, attendees revealed that most view AI's potential regarding power as a “promise,” rather than a “peril,” although a considerable portion remain uncertain about the ultimate impact. When asked about priorities in power supply for computing facilities, half of the respondents selected carbon intensity as their top concern, with reliability and cost following.

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3 Questions: How MIT’s venture studio is partnering with MIT labs to solve “holy grail” problems

MIT Proto Ventures is the Institute’s in-house venture studio — a program designed not to support existing startups, but to create entirely new ones from the ground up. Operating at the intersection of breakthrough research and urgent real-world problems, Proto Ventures proactively builds startups that leverage MIT technologies, talent, and ideas to address high-impact industry challenges. 

Each venture-building effort begins with a “channel” — a defined domain such as clean energy, fusion, or AI in health care — where MIT is uniquely positioned to lead, and where there are pressing real-world problems needing solutions. Proto Ventures hires full-time venture builders, deeply technical entrepreneurs who embed in MIT labs, connect with faculty, scout promising inventions, and explore unmet market needs. These venture builders work alongside researchers and aspiring founders from across MIT who are accepted into Proto Ventures’ fellowship program to form new teams, shape business concepts, and drive early-stage validation. Once a venture is ready to spin out, Proto Ventures connects it with MIT’s broader innovation ecosystem, including incubation programs, accelerators, and technology licensing. 

David Cohen-Tanugi SM '12, PhD '15 has been the venture builder for the fusion and clean energy channel since 2023.  

Q: What are the challenges of launching startups out of MIT labs? In other words, why does MIT need a venture studio? 

A: MIT regularly takes on the world’s “holy grail” challenges, such as decarbonizing heavy industry, preventing future pandemics, or adapting to climate extremes. Yet despite its extraordinary depth in research, too few of MIT’s technical breakthroughs evolve into successful startups targeting these problems. Not enough technical breakthroughs in MIT labs are turning into commercial efforts to address these highest-impact problems. 

There are a few reasons for this. Right now, it takes a great deal of serendipity for a technology or idea in the lab to evolve into a startup project within the Institute’s ecosystem. Great startups don’t just emerge from great technology alone — they emerge from combinations of great technology, unmet market needs, and committed people. 

A second reason is that many MIT researchers don’t have the time, professional incentives, or skill set to commercialize a technology. They often lack someone that they can partner with, someone who is technical enough to understand the technology but who also has experience bringing technologies to market. 

Finally, while MIT excels at supporting entrepreneurial teams that are already in motion — thanks to world-class accelerators, mentorship services, and research funding programs — what’s missing is actually further upstream: a way to deliberately uncover and develop venture opportunities that haven’t even taken shape yet.  

MIT needs a venture studio because we need a new, proactive model for research translation — one that breaks down silos and that bridges deep technical talent with validated market needs. 

Q: How do you add value for MIT researchers?

A: As a venture builder, I act as a translational partner for researchers — someone who can take the lead on exploring commercial pathways in partnership with the lab. Proto Ventures fills the gap for faculty and researchers who believe their work could have real-world applications but don’t have the time, entrepreneurial expertise, or interested graduate students to pursue them. Proto Ventures fills that gap. 

Having done my PhD studies at MIT a decade ago, I’ve seen firsthand how many researchers are interested in impact beyond academia but don’t know where to start. I help them think strategically about how their work fits into the real market, I break down tactical blockers such as intellectual property conversations or finding a first commercial partner, and I roll up my sleeves to do customer discovery, identify potential co-founders, or locate new funding opportunities. Even when the outcome isn’t a startup, the process often reveals new collaborators, use cases, or research directions. We’re not just scouting for IP — we’re building a deeper culture of tech translation at MIT, one lab at a time. 

Q: What counts as a success? 

A: We’ve launched five startups across two channels so far, including one that will provide energy-efficient propulsion systems for satellites and another that is developing advanced power supply units for data centers.  

But counting startups is not the only way to measure impact. While embedded at the MIT Plasma Science and Fusion Center, I have engaged with 75 researchers in translational activities — many for the first time. For example, I’ve helped research scientist Dongkeun Park craft funding proposals for next-generation MRI and aircraft engines enabled by high-temperature superconducting magnets. Working with Mike Nour from the MIT Sloan Executive MBA program, we’ve also developed an innovative licensing strategy for Professor Michael P. Short and his antifouling coating technology. Sometimes it takes an outsider like me to connect researchers across departments, suggest a new collaboration, or unearth an overlooked idea. Perhaps most importantly, we’ve validated that this model works: embedding entrepreneurial scientists in labs changes how research is translated. 

We’ve also seen that researchers are eager to translate their work — they just need a structure and a partner to help them do it. That’s especially true in the hard tech in which MIT excels. That’s what Proto Ventures offers. And based on our early results, we believe this model could be transformative not just for MIT, but for research institutions everywhere. 

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The high-tech wizardry of integrated photonics

Inspired by the “Harry Potter” stories and the Disney Channel show “Wizards of Waverly Place,” 7-year-old Sabrina Corsetti emphatically declared to her parents one afternoon that she was, in fact, a wizard.

“My dad turned to me and said that, if I really wanted to be a wizard, then I should become a physicist. Physicists are the real wizards of the world,” she recalls.

That conversation stuck with Corsetti throughout her childhood, all the way up to her decision to double-major in physics and math in college, which set her on a path to MIT, where she is now a graduate student in the Department of Electrical Engineering and Computer Science.

While her work may not involve incantations or magic wands, Corsetti’s research centers on an area that often produces astonishing results: integrated photonics. A relatively young field, integrated photonics involves building computer chips that route light instead of electricity, enabling compact and scalable solutions for applications ranging from communications to sensing.

Corsetti and her collaborators in the Photonics and Electronics Research Group, led by Professor Jelena Notaros, develop chip-sized devices which enable innovative applications that push the boundaries of what is possible in optics.

For instance, Corsetti and the team developed a chip-based 3D printer, small enough to sit in the palm of one’s hand, that emits a reconfigurable beam of light into resin to create solid shapes. Such a device could someday enable a user to rapidly fabricate customized, low-cost objects on the go.

She also contributed to creating a miniature “tractor beam” that uses a beam of light to capture and manipulate biological particles using a chip. This could help biologists study DNA or investigate the mechanisms of disease without contaminating tissue samples.

More recently, Corsetti has been working on a project in collaboration with MIT Lincoln Laboratory, focused on trapped-ion quantum computing, which involves the manipulation of ions to store and process quantum information.

“Our team has a strong focus on designing devices and systems that interact with the environment. The opportunity to join a new research group, led by a supportive and engaged advisor, that works on projects with a lot of real-world impacts, is primarily what drew me to MIT,” Corsetti says.

Embracing challenges

Years before she set foot in a research lab, Corsetti was a science- and math-focused kid growing up with her parents and younger brother in the suburbs of Chicago, where her family operates a structural steelwork company.

Throughout her childhood, her teachers fostered her love of learning, from her early years in the Frankfort 157-C school district through her time at the Lincoln-Way East High School.

She enjoyed working on science experiments outside the classroom and relished the chance to tackle complex conundrums during independent study projects curated by her teachers (like calculating the math behind the Brachistochrone Curve, or the shortest path between two points, which was famously solved by Isaac Newton).

Corsetti decided to double-major in physics and math at the University of Michigan after graduating from high school a year early.

“When I went to the University of Michigan, I couldn’t wait to get started. I enrolled in the toughest math and physics track right off the bat,” she recalls.

But Corsetti soon found that she had bitten off a bit more than she could chew. A lot of her tough undergraduate courses assumed students had prior knowledge from AP physics and math classes, which Corsetti hadn’t taken because she graduated early.

She met with professors, attended office hours, and tried to pick up the lessons she had missed, but felt so discouraged she contemplated switching majors. Before she made the switch, Corsetti decided to try working in a physics lab to see if she liked a day in the life of a researcher.

After joining Professor Wolfgang Lorenzon’s lab at Michigan, Corsetti spent hours working with grad students and postdocs on a hands-on project to build cells that would hold liquid hydrogen for a particle physics experiment.

As they collaborated for hours at a time to roll material into tubes, she peppered the older students with questions about their experiences in the field.

“Being in the lab made me fall in love with physics. I really enjoyed that environment, working with my hands, and working with people as part of a bigger team,” she says.

Her affinity for hands-on lab work was amplified a few years later when she met Professor Tom Schwarz, her research advisor for the rest of her time at Michigan.

Following a chance conversation with Schwarz, she applied to a research abroad program at CERN in Switzerland, where she was mentored by Siyuan Sun. There, she had the opportunity to join thousands of physicists and engineers on the ATLAS project, writing code and optimizing circuits for new particle-detector technologies.

“That was one of the most transformative experiences of my life. After I came back to Michigan, I was ready to spend my career focusing on research,” she says.

Hooked on photonics

Corsetti began applying to graduate schools but decided to shift focus from the more theoretical particle physics to electrical engineering, with an interest in conducting hands-on chip-design and testing research.

She applied to MIT with a focus on standard electronic-chip design, so it came as a surprise when Notaros reached out to her to schedule a Zoom call. At the time, Corsetti was completely unfamiliar with integrated photonics. However, after one conversation with the new professor, she was hooked.

“Jelena has an infectious enthusiasm for integrated photonics,” she recalls. “After those initial conversations, I took a leap of faith.”

Corsetti joined Notaros’ team as it was just getting started. Closely mentored by a senior student, Milica Notaros, she and her cohort grew immersed in integrated photonics.

Over the years, she’s particularly enjoyed the collaborative and close-knit nature of the lab and how the work involves so many different aspects of the experimental process, from design to simulation to analysis to hardware testing.

“An exciting challenge that we’re always running up against is new chip-fabrication requirements. There is a lot of back-and-forth between new application areas that demand new fabrication technologies, followed by improved fabrication technologies motivating additional application areas. That cycle is constantly pushing the field forward,” she says.

Corsetti plans to stay at the cutting edge of the field after graduation as an integrated-photonics researcher in industry or at a national lab. She would like to focus on trapped-ion quantum computing, which scientists are rapidly scaling up toward commercially viable systems, or other high-performance computing applications.

“You really need accelerated computing for any modern research area. It would be exciting and rewarding to contribute to high-performance computing that can enable a lot of other interesting research areas,” she says.

Paying it forward

In addition to making an impact with research, Corsetti is focused on making a personal impact in the lives of others. Through her involvement in MIT Graduate Hillel, she joined the Jewish Big Brothers Big Sisters of Boston, where she volunteers for the friend-to-friend program.

Participating in the program, which pairs adults who have disabilities with friends in the community for fun activities like watching movies or painting has been an especially uplifting and gratifying experience for Corsetti.

She’s also enjoyed the opportunity to support, mentor, and bond with her fellow MIT EECS students, drawing on the advice she’s received throughout her own academic journey.

“Don’t trust feelings of imposter syndrome,” she advises others. “Keep moving forward, ask for feedback and help, and be confident that you will reach a point where you can make meaningful contributions to a team.”

Outside the lab, she enjoys playing classical music on the clarinet (her favorite piece is Leonard Bernstein’s famous overture to “Candide”), reading, and caring for a family of fish in her aquarium.

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MIT Open Learning bootcamp supports effort to bring invention for long-term fentanyl recovery to market

The Substance Use Disorders Ventures Bootcamp ignites innovators like Evan Kharasch to turn research breakthroughs into treatments for substance use disorder.

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How repetition helps art speak to us

MIT engineers develop electrochemical sensors for cheap, disposable diagnostics

Using an inexpensive electrode coated with DNA, MIT researchers have designed disposable diagnostics that could be adapted to detect a variety of diseases, including cancer or infectious diseases such as influenza and HIV.

These electrochemical sensors make use of a DNA-chopping enzyme found in the CRISPR gene-editing system. When a target such as a cancerous gene is detected by the enzyme, it begins shearing DNA from the electrode nonspecifically, like a lawnmower cutting grass, altering the electrical signal produced.

One of the main limitations of this type of sensing technology is that the DNA that coats the electrode breaks down quickly, so the sensors can’t be stored for very long and their storage conditions must be tightly controlled, limiting where they can be used. In a new study, MIT researchers stabilized the DNA with a polymer coating, allowing the sensors to be stored for up to two months, even at high temperatures. After storage, the sensors were able to detect a prostate cancer gene that is often used to diagnose the disease.

The DNA-based sensors, which cost only about 50 cents to make, could offer a cheaper way to diagnose many diseases in low-resource regions, says Ariel Furst, the Paul M. Cook Career Development Assistant Professor of Chemical Engineering at MIT and the senior author of the study.

“Our focus is on diagnostics that many people have limited access to, and our goal is to create a point-of-use sensor. People wouldn’t even need to be in a clinic to use it. You could do it at home,” Furst says.

MIT graduate student Xingcheng Zhou is the lead author of the paper, published June 30 in the journal ACS Sensors. Other authors of the paper are MIT undergraduate Jessica Slaughter, Smah Riki ’24, and graduate student Chao Chi Kuo.

An inexpensive sensor

Electrochemical sensors work by measuring changes in the flow of an electric current when a target molecule interacts with an enzyme. This is the same technology that glucose meters use to detect concentrations of glucose in a blood sample.

The electrochemical sensors developed in Furst’s lab consist of DNA adhered to an inexpensive gold leaf electrode, which is laminated onto a sheet of plastic. The DNA is attached to the electrode using a sulfur-containing molecule known as a thiol.

In a 2021 study, Furst’s lab showed that they could use these sensors to detect genetic material from HIV and human papillomavirus (HPV). The sensors detect their targets using a guide RNA strand, which can be designed to bind to nearly any DNA or RNA sequence. The guide RNA is linked to an enzyme called Cas12, which cleaves DNA nonspecifically when it is turned on and is in the same family of proteins as the Cas9 enzyme used for CRISPR genome editing.

If the target is present, it binds to the guide RNA and activates Cas12, which then cuts the DNA adhered to the electrode. That alters the current produced by the electrode, which can be measured using a potentiostat (the same technology used in handheld glucose meters).

“If Cas12 is on, it’s like a lawnmower that cuts off all the DNA on your electrode, and that turns off your signal,” Furst says.

In previous versions of the device, the DNA had to be added to the electrode just before it was used, because DNA doesn’t remain stable for very long. In the new study, the researchers found that they could increase the stability of the DNA by coating it with a polymer called polyvinyl alcohol (PVA).

This polymer, which costs less than 1 cent per coating, acts like a tarp that protects the DNA below it. Once deposited onto the electrode, the polymer dries to form a protective thin film.

“Once it’s dried, it seems to make a very strong barrier against the main things that can harm DNA, such as reactive oxygen species that can either damage the DNA itself or break the thiol bond with the gold and strip your DNA off the electrode,” Furst says.

Successful detection

The researchers showed that this coating could protect DNA on the sensors for at least two months, and it could also withstand temperatures up to about 150 degrees Fahrenheit. After two months, they rinsed off the polymer and demonstrated that the sensors could still detect PCA3, a prostate cancer gene that can be found in urine.

This type of test could be used with a variety of samples, including urine, saliva, or nasal swabs. The researchers hope to use this approach to develop cheaper diagnostics for infectious diseases, such as HPV or HIV, that could be used in a doctor’s office or at home. This approach could also be used to develop tests for emerging infectious diseases, the researchers say.

A group of researchers from Furst’s lab was recently accepted into delta v, MIT’s student venture accelerator, where they hope to launch a startup to further develop this technology. Now that the researchers can create tests with a much longer shelf-life, they hope to begin shipping them to locations where they could be tested with patient samples.

“Our goal is to continue to test with patient samples against different diseases in real world environments,” Furst says. “Our limitation before was that we had to make the sensors on site, but now that we can protect them, we can ship them. We don’t have to use refrigeration. That allows us to access a lot more rugged or non-ideal environments for testing.”

The research was funded, in part, by the MIT Research Support Committee and a MathWorks Fellowship.

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