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QS-21 is a potent vaccine adjuvant currently sourced by extraction from the Chilean soapbark tree. It is a key component of human vaccines for shingles, malaria, coronavirus disease 2019 and others under development. The structure of QS-21 consists of a glycosylated triterpene scaffold coupled to a complex glycosylated 18-carbon acyl chain that is critical for immunostimulant activity. We previously identified the early pathway steps needed to make the triterpene glycoside scaffold; however, the biosynthetic route to the acyl chain, which is needed for stimulation of T cell proliferation, was unknown. Here, we report the biogenic origin of the acyl chain, characterize the series of enzymes required for its synthesis and addition and reconstitute the entire 20-step pathway in tobacco, thereby demonstrating the production of QS-21 in a heterologous expression system. This advance opens up unprecedented opportunities for bioengineering of vaccine adjuvants, investigating structure-activity relationships and understanding the mechanisms by which these compounds promote the human immune response.

Modular polyketide synthases (PKSs) are polymerases that employ α-carboxyacyl-CoAs as extender substrates. This enzyme family contains several catalytic modules, where each module is responsible for a single round of polyketide chain extension. Although PKS modules typically use malonyl-CoA or methylmalonyl-CoA for chain elongation, many other malonyl-CoA analogues are used to diversify polyketide structures in nature. Previously, we developed a method to alter an extension substrate of a given module by exchanging an acyltransferase (AT) domain while maintaining protein folding. Here, we report in vitro polyketide biosynthesis by 13 PKSs (the wild-type PKS and 12 AT-exchanged PKSs with unusual ATs) and 14 extender substrates. Our ∼200 in vitro reactions resulted in 13 structurally different polyketides, including several polyketides that have not been reported. In some cases, AT-exchanged PKSs produced target polyketides by >100-fold compared to the wild-type PKS. These data also indicate that most unusual AT domains do not incorporate malonyl-CoA and methylmalonyl-CoA but incorporate various rare extender substrates that are equal to in size or slightly larger than natural substrates. We developed a computational workflow to predict the approximate AT substrate range based on active site volumes to support the selection of ATs. These results greatly enhance our understanding of rare AT domains and demonstrate the benefit of using the proposed PKS engineering strategy to produce novel chemicals in vitro.

Polyketide synthase (PKS) engineering is an attractive method to generate new molecules such as commodity, fine and specialty chemicals. A significant challenge is re-engineering a partially reductive PKS module to produce a saturated β-carbon through a reductive loop (RL) exchange. In this work, we sought to establish that chemoinformatics, a field traditionally used in drug discovery, offers a viable strategy for RL exchanges. We first introduced a set of donor RLs of diverse genetic origin and chemical substrates  into the first extension module of the lipomycin PKS (LipPKS1). Product titers of these engineered unimodular PKSs correlated with chemical structure similarity between the substrate of the donor RLs and recipient LipPKS1, reaching a titer of 165 mg/L of short-chain fatty acids produced by the host Streptomyces albus J1074. Expanding this method to larger intermediates that require bimodular communication, we introduced RLs of divergent chemosimilarity into LipPKS2 and determined triketide lactone production. Collectively, we observed a statistically significant correlation between atom pair chemosimilarity and production, establishing a new chemoinformatic method that may aid in the engineering of PKSs to produce desired, unnatural products.

Non-ribosomal peptides (NRPs) constitute a diverse class of valuable secondary metabolites, with potential industrial applications including use as pharmaceuticals, polymers and dyes. Current industrial production of dyes is predominantly achieved via chemical synthesis, which can involve toxic precursors and generate hazardous byproducts. Thus, alternative routes of dye production are highly desirable to enhance both workplace safety and environmental sustainability. Correspondingly, biological synthesis of dyes from renewable carbon would serve an ideal green chemistry paradigm. Therefore, we engineered the fungal host Rhodosporidium toruloides to produce the blue pigment indigoidine, an NRP with potential applications in the dye industry, using various low-cost carbon and nitrogen sources. To demonstrate production from renewable carbon sources and assess process scalability we produced indigoidine in 2 L bioreactors, reaching titers of 2.9 ± 0.8 g L-1 using a sorghum lignocellulosic hydrolysate in a batch process and 86.3 ± 7.4 g L-1 using glucose in a high-gravity fed-batch process. This study represents the first heterologous production of an NRP in R. toruloides, thus extending the range of microbial hosts that can be used for sustainable, heterologous production of NRPs. In addition, this is the first demonstration of producing an NRP using lignocellulose. These results highlight the potential of R. toruloides for the sustainable, and scalable production of NRPs, with the highest reported titer of indigoidine or any heterologously produced NRP to date.

A new mode of mechanical entanglement in extended structures is described where 1D organic ribbons of corner-sharing squares are mutually interlocked to form 3D woven covalent organic framework-500, COF-500. Reaction of aldehyde-functionalized tetrahedral Cu(PDB)2PO2Ph2 complexes (PDB = 4,4'-(1,10-phenanthroline-2,9-diyl)dibenzaldehyde) with rectangular tetratopic ETTBA (4',4‴,4''''',4''''‴-(ethene-1,1,2,2-tetrayl)tetrakis([1,1'-biphenyl]-4-amine)) linkers through imine condensation, yielded a crystalline porous metalated COF, COF-500-Cu, with pts topology. Upon removal of the Cu(I) ions, the individual 1D square ribbons in the demetalated form (COF-500) are held together only by mechanical interlocking of rings, which allows their collective movement to produce a narrow-pore form, as evidenced by nitrogen adsorption and solid-state photoluminescence studies. When exposed to tetrahydrofuran vapor, the interlocking ribbons can dynamically move away from each other to reopen up the structure. The structural integrity of COF-500 is maintained during its dynamics because the constituent square ribbons cannot part company due to spatial confinement imparted by their interlocking nature.

The synthesis of new isoreticular non-interpenetrated woven covalent organic frameworks (COFs) was achieved by linking aldehyde-functionalized copper(I) bisphenanthroline complexes with benzidine linkers in the presence of a bulky anion, diphenylphosphinate (PO2Ph2-) to give metalated COF-506-Cu and, upon removal of copper(I), the demetalated COF-506. The structures of these COFs were determined by a combination of powder X-ray diffraction and electron microscopy techniques. Guest-accessibility to the pores of the two frameworks was examined by vapor and dye inclusion studies and compared to the already reported doubly-interpenetrated COF-505-Cu.  Remarkably, COF-506 was found to take up guest molecules that exceed the size of the COF-506-Cu pores, thus giving credence to the notion of a novel mode of motional dynamics in solids we term 'adaptive inclusion'.