Rapid transport.
Highly localized control.
PSI Research Labs
Cells don’t experience averages.
Scale exposure, not assumptions.
FlowCast AI applies empirical correlations, interpolation, extrapolation, and data analysis derived from physical experimental measurements to compare process environments across scales and platforms.
FLOWCAST AI
Experimental scale-up workbench
Cellular demand
O₂ · nutrients · kinetics
→
Vessel capacity
mixing · kLa · control
Experiment-derived process environment
across scales + platforms
2 LDevelopment
200 LPilot
2,000 LProduction
The scale-up problem
Cells don’t experience scale.
They experience environment.
A cell has no concept of vessel volume, impeller diameter, agitation rate, or platform.
It experiences only the fluid immediately around it—oxygen, nutrients, pH, metabolites, gas exposure, shear, and the way those conditions change as it moves.
Scale-up becomes difficult when that local environment, or our ability to control it, changes in ways that matter to the process.
That is the scale-up problem.
Meet FlowCast AI
A scale-up workbench built around what cells actually experience.
FlowCast AI is built around physical experimental testing and characterization, laboratory measurement and validation, and empirical analysis derived from physical experimental data.
Empirical correlations · interpolation · extrapolation · visualization · data analysis
FLOWCAST MODULE
Reaction Explorer
Define and explore the cellular demand side of the process: reaction kinetics, oxygen uptake, nutrient consumption, and process targets.
Core question
What does the biology demand from the vessel?
CELLULAR DEMAND ↔ VESSEL CAPACITY
Demand
Environment
Control
The physics
Scale-up isn’t magic. It’s physics.
Mixing, mass transfer, transport, reaction, and control shape the environment cells see. By measuring those effects directly, unexplained scale behavior becomes an experimentally testable engineering problem.
01Operating conditions
→
02Transport + mixing
→
03Local environment
→
04Cell exposure
→
05Process performance
We turn scale-up mysteries into solvable engineering problems.
EXPERIMENTAL LAB
Real vessels.
Real measurements.
Real physics. Upload your lab/vessel image in Appearance → Customize.
Real measurements.
Real physics. Upload your lab/vessel image in Appearance → Customize.
Experimental foundation
FlowCast AI is grounded in experiment.
We measure vessel behavior directly.
PSI Research Labs develops purpose-built experimental systems to characterize mixing, oxygen transfer, dissolved oxygen, transport, gradients, and control response in standard single-use bioreactors and other vessel platforms.
EXPERIMENTMeasure local process behavior.
CHARACTERIZEIdentify the physics creating the environment.
ANALYZEUse FlowCast AI to compare experiment-derived data across scales and platforms.
CONTROL + SCALEFind operating strategies that preserve process experience.
Across scales and platforms
Same process.
Different vessel.
What changed for the cells?
Longer transport.
Control interaction.
Spatial exposure.
Scale-dependent physics.
FLOWCAST AIMake the differences explicit.
Compare the environments created by different vessel sizes and platforms instead of assuming that matching a bulk setpoint reproduces the process.
What PSIRL does
Experimental measurement first.
Physical experimental testing & characterization
Purpose-built vessel testing to measure real process behavior across operating conditions, scales, and platforms.
Laboratory measurement & validation
Localized sensing and laboratory measurements for mixing, oxygen transfer, dissolved oxygen, gradients, and related process variables.
Empirical analysis from physical data
Correlations, interpolation, extrapolation, and data analysis methods derived from physical experimental measurements.
Clear boundary:
PSI Research Labs does not provide Computational Fluid Dynamics (CFD) software. FlowCast AI uses physical experimental data, empirical correlations, interpolation, extrapolation, visualization, and data analysis.
The point
The point is not the map.
The point is successful process transfer.
Bulk measurements describe what the vessel reports. Exposure describes what the process experiences. FlowCast AI connects the two through empirical, experiment-derived analysis so scale-up can be compared, diagnosed, controlled, and improved.
Measure→Understand→Control→Scale
PSI Research Labs
What changes when your process scales?
Measure what the cells are actually experiencing. Compare what changes across scales and platforms. Use physical experimental data to turn the difference into a solvable engineering problem.