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these commercial microarray-based platforms vary widely, lengths of up to 350nt have been attained, more than doubling the ~150nt achieved a decade prior [22]. Error rates as low as 1in 2000nt are also possible with today’s synthesizers. The oligo lengths achieved by modern oligo synthesis platforms, however, will inevita­bly plateau as phosphoramidite reaction efciencies approach 100%. Nevertheless, synthesis density—how many oligos can be synthesized per chip—is expected to grow with the continued miniaturization of synthesis platforms.
R. L. Nugent and A. K. Sato

3.3 Gene Synthesis

As discussed above, oligo synthesis methods, although substantially improved over the years, still struggle to synthesize oligos longer than a few hundred nucleotides. As a result, methods were developed to stitch short, chemically synthesized oligos into dsDNA gene fragments, called gene synthesis. Although the rst successful attempts at gene synthesis utilized T4 DNA ligase to stitch oligos together sequen­tially, the discovery of new enzymes (thermostable ligases) and technologies (PCR) paved the way for one-pot gene syntheses in the subsequent decades. These strate­gies, subject to continued innovation within the context of array-based oligo synthe­sis, form the basis of modern commercial gene synthesis platforms.
3.3.1 Early DNA Assembly Methods
The rst synthetic gene took more than 5 years to synthesize. Working with limiting synthetic chemistries, Khorana and colleagues generated the rst synthetic genes by chemically synthesizing, annealing, phosphorylating, and ultimately ligating a series of short (8–12nt) oligos [27, 28]. Without thermostable ligases, Khorana’s group resorted to sequential ligation reactions to tack on each chemically synthe­sized oligo. One-pot, ligation-dependent gene synthesis was not demonstrated until 1998 [29]. Ligation-based DNA assembly methods have inherently low error rates, unlike the PCR-based methods that have largely, but not completely, superseded them. At least two commercial options for ligation-based gene synthesis exist today: Blue Heron Biotechnology (acquired by Eurons Genomics in 2019) and Sloning BioTechnology GmbH (acquired by MorphoSys AG in 2010).
The invention of PCR in the 1980s spawned multiple PCR-based methods for DNA assembly. Yet, to this day, Willem Stemmer’s polymerase chain assembly (PCA) method [30] remains the most common among them (Fig.3.2). PCA, also called oligo shufing, harnesses the ability of DNA polymerases to ll in gaps in complementary single-stranded DNA by PCR extension. DNA polymerases ran­domly form larger and larger assemblies during thermocycling, and the nal assem­bly, once formed, is ultimately amplied by PCR using primers unique to each end of the fully assembled DNA fragment. Stemmer and colleagues leveraged this
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Fig. 3.2 Classic gene synthesis. (Adapted from Stemmer etal. [30])
method to assemble as many as 134 chemically synthesized oligos into DNA frag­ments up to 2.7kb in length [30]. The numerous other PCR-based assembly meth­ods have been reviewed in detail elsewhere [31] and will not be discussed here, except to note that they largely involve a subassembly approach whereby smaller fragments are joined rst into subassemblies, which are subsequently stitched together into full-length gene fragments.
3.3.2 Array-Based Gene Synthesis
By necessity, early gene synthesis attempts used column-synthesized oligos as building blocks. The advent of microarray-based oligo synthesizers promised increased throughput while posing new challenges for gene synthesis. Compared to column-synthesized oligos, array-synthesized oligos are produced as a complex
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mixture of low-quantity (femtomolar) and relatively low-quality oligos. These fea­tures—complexity, quantity, and quality—have complicated gene synthesis using array-synthesized oligos.
Current microarray oligo synthesizers can generate one million oligos on a sin­gle chip, with each oligo synthesized at the atto- or femtomolar scale. Although these minute quantities reduce the overall cost of oligo synthesis by minimizing reagent use, they are insufcient for most DNA assembly methods. Moreover, the complexity of the synthesized oligo pools can lead to unintended hybridization of oligos during assembly. Two general strategies have been deployed to solve these concentration and complexity problems: amplifying oligos by PCR and miniatur­izing the volume of the assembly reaction.
Amplifying oligos by PCR is the more common method for increasing the con­centration of array-synthesized oligos for gene synthesis. Tian etal. [32] solved this problem by attaching a common primer sequence and a nicking endonuclease rec­ognition site to the 3-end of synthesized oligos. Once synthesized, oligos could be amplied from the 3-end by primer extension and the resulting complementary strands cleaved by a nicking endonuclease, effectively amplifying the array­synthesized pool. The strategy, however, fails when applied to more complex (>1000 oligo) pools [33]. Kosuri etal. [34] conceived a barcoding strategy whereby primer sites were appended to each end of a subset of oligos to enable their selective ampli­cation. This strategy enabled multiple subpools to be amplied from the master oligo pool. Although these PCR-based methods are straightforward, they are also error-prone. Not only is PCR inherently error-prone, but extending the length of oligo synthesis to incorporate primer sites can increase the error rate of the synthesis process, too.
Miniaturizing the assembly reaction is a less common, but nonetheless effective, solution to the concentration problem. It also addresses the complexity problem. Kong etal. [35] demonstrated the feasibility of this approach by partitioning oligo synthesis and assembly into 500nL microuidic reactors. Quan etal. [26] utilized an inkjet printing approach to spatially control the synthesis of oligos into physi­cally separated microwells for subsequent gene synthesis.
Overall, the success of these strategies has led to their commercialization, in principle, by Gen9 (now Ginkgo Bioworks) and Twist Bioscience.
3.3.3 Error Correction andSequence Validation
If oligo synthesis were a perfect process, gene synthesis would be straightforward and relatively quick. Unfortunately, it is not. Errors in oligo synthesis lead to errors in gene synthesis, as error-containing oligos are assembled along with perfect (error-free) ones. Traditionally, error-free gene fragments were identied by cloning and sequencing individual clones. This laborious and expensive process serves as a bottleneck in the discovery workow. Because biological features are encoded by DNA, even minor errors can have an outsized impact on the functionality of the nal
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product. The quality of array-synthesized oligos is generally lower than that of their column-synthesized counterparts, necessitating methods for error ltration and correction.
The process of array-based gene synthesis spans multiple error-prone steps. Array-based oligo synthesizers can generate errors as a result of inefciencies in the synthesis cycle, side reactions (i.e., depurination), and deviations in spatially con­trolled steps (as discussed in Sect. 3.2.3 Modern Oligo Synthesis Platforms). DNA assembly methods, particularly the PCR-based ones in common use, are as error­prone as the DNA polymerases they use. To mitigate the impact of these error sources on gene synthesis, two general strategies have been developed to lter error­free oligos from those containing errors: those that use mismatch-binding/cleaving proteins to remove errors and those that enrich for error-free DNA.These strategies are discussed briey below; see Ma etal. [23] for an in-depth review on the topic.
Mismatch detection is commonly used to lter errors in synthetic genes (i.e., duplexes). This strategy involves using a mismatch-binding/cleaving protein to either lter out or degrade, respectively, DNA assemblies containing errors. Mismatches are generated by denaturing the DNA duplexes and reannealing them; this process causes error-containing strands to randomly pair with error-free strands. Once this is done, mismatch-binding proteins (e.g., MutS) [36] or mismatch­cleaving enzymes (e.g., T7 endonuclease 1) [37, 38] can be used to selectively iso­late or degrade error-containing duplexes, respectively. The choice of strategy depends on the length of the gene fragments and how many errors they contain; mismatch cleavage is generally preferred for both long and error-rich fragments [39].
Several groups have used next-generation sequencing (NGS) to lter error­containing gene fragments. Among them, the most accessible is dial-out PCR [40,
41], which involves appending primer sites to the ends of each gene fragment, iden-
tifying error-free fragments by sequencing, and selectively amplifying them by PCR.This approach is highly cost-efcient but time-consuming. Other sequencing­based methods have been proposed, but they are either low-throughput, incompati­ble with some NGS platforms, or require specialized equipment [15].

3.4 New Discovery Bottleneck

Modern DNA reading (sequencing) and writing (synthesis) technologies allow bio­engineering to be approached more systematically. This systematic approach, referred to as the design-build-test-learn (DBTL) cycle, starts by modeling a biopro­cess, including all the parts (e.g., oligos and gene fragments) and processes that will be used to produce and evaluate a bioengineered product; proceeds through the building and testing of the bioengineered product; and ends with a learning phase, where insights gained are used to inform the next iteration of the cycle. Traditionally, low-throughput oligo synthesis has bottlenecked the cycle at the build phase. Now, with modern gene synthesis platforms like Twist Bioscience’s, which can synthe­size nearly 10,000 gene fragments (or >one million oligos) on a silicon chip the size
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of a 96-well plate, the bottleneck has been shifted to the testing and learning phases of the cycle.
In the next section, we discuss how modern gene synthesis technologies have transformed the antibody discovery process by enabling the fabrication of massive synthetic antibody libraries.
3.4.1 Evolution ofAntibody Discovery
Antibodies represent the largest class of biopharmaceuticals on the market. The rst therapeutic monoclonal antibody (mAb), muromonab-CD3 (Orthoclone OKT3; Janssen-Cilag), entered the market in 1986 and was developed using the traditional hybridoma method [42]. The rst therapeutic human mAb came a decade and a half later in 2002 with the approval of adalimumab (Humira; Abbott), a feat that was made possible by the invention of phage display technology [43]. Spurred by the concurrent development of molecular biology methods (e.g., molecular cloning, oligo synthesis, and gene synthesis), mAb-generating technologies have matured over the past half century. In this section, we discuss how modern gene synthesis platforms have expanded and hastened the therapeutic antibody discovery process.
3.4.1.1 Hybridoma Technology
The year 1975 saw the emergence of a breakthrough technology for the facile pro­duction of mAbs: hybridomas [44]. George Köhler invented the technology in César Milstein’s lab by fusing mortal B-cells with transformed ones (i.e., myelomas) [45]. Unlike the myeloma–myeloma fusions attempted by Milstein previously, Köhler’s hybridomas produced highly specic antibodies of a single specicity. Hybridomas unleashed mAbs onto the world, contributing to their pervasiveness in the labora­tory and clinical settings.
Hybridomas continue to be used to this day. As of 2020, greater than 90% of therapeutic mAbs that have received regulatory approval were generated using hybridoma technology. Despite this clear success, using hybridomas to produce therapeutic mAbs can be time-consuming and costly. Also, the technology cannot be used to generate mAbs against toxic or nonimmunogenic antigens. Cellular sta­bility and lack of direct access to antibody genes are additional challenges faced by hybridoma technology [46].
3.4.1.2 Phage Display Technology
The invention of molecular technologies such as PCR and recombinant DNA gave rise to the eld of antibody engineering in the late 1980s. Skerra and Pluckthun [47] were the rst to express recombinant antibody fragments in Escherichia coli.
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Shortly after, Orlandi etal. [48] demonstrated that antibody domains could be iso­lated using PCR without a priori knowledge of their coding sequences. The rst antibody libraries followed, generated via PCR by Ward etal. [49] and then by Huse etal. [50]. These studies demonstrated that antibody genes could be isolated and screened for antigen binding in a library format, laying the foundation for the inven­tion of phage display technology by McCafferty etal. [51] a year later. The inven­tion spurred the development of hundreds of antibody libraries over the next decade and a half. By 2006, over 30 companies were using phage display in their discovery platforms [52].
The invention of phage displays substantially increased the throughput of anti­body discovery. Unlike the laborious process of screening individual hybridoma clones, phage display enables the screening of naïve, immunized, or synthetic rep­ertoires en masse. Phage display involves fusing the genes encoding antibody frag­ments and phage coat proteins together. This process results in the display of antibody fragments on the coat protein surface of phages. The resulting phages can be subsequently screened for antigen binding by iteratively enriching them on antigen- immobilized plates. The process is highly amenable to automation, much more so than hybridoma technology [53]. It is also easily interfaced with high­throughput gene synthesis technologies.
3.4.1.3 Synthetic Antibody Library Construction
The diversication processes used to generate diverse antibody libraries mimic the natural processes that occur in situ [54]. The natural process starts with the combi­natorial recombination of V, D, and J gene segments in B-lymphocytes and ends with afnity maturation via somatic hypermutation in response to antigenic stimula­tion. Similarly, the recombinant process involves combinatorial shufing of cloned, semi-synthetic, or synthetic gene fragments within established antibody frame­works to obtain an antibody library. Subsequent afnity maturation occurs during phage display. The afnity of antibody candidates can be matured further by gener­ating a secondary library based on candidates identied from an initial library, although this is not necessary. Indeed, antibody fragments with picomolar afnities are routinely isolated from antibody libraries by phage display without the need for additional afnity maturation [53].
Unlike natural and immunized antibody libraries, synthetic antibody libraries incorporate synthetic sources of diversity in their complementarity-determining regions (CDRs). Synthetic diversity can be sourced from degenerate primers, syn­thetic trinucleotides, and oligo pools of discrete sequences. The application of these methods to the construction of semi- and fully synthetic antibody libraries is out­lined below.
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Semi-Synthetic Libraries
The rst semi-synthetic antibody libraries obtained their CDR diversity from degen­erate primers [55, 56]. These libraries were constructed by shufing a bank of germ­line heavy chain variable regions (VH), which spanned CDRs 1 and 2; adding a third, diversied CDR (CDR3) by PCR amplication using NNK/NNS degenerate prim­ers (N=any nucleotide; K=G/T; S= G/C); and cloning the resulting VH and a human light chain (VL) as scFv fragments (Fig. 3.3). Later degenerate antibody libraries improved upon these initial libraries by minimizing the diversity of certain residues to that found in natural antibodies [57] or by leveraging favorable antibody frameworks [58]. These early libraries were relatively modest in size, at least by present-day standards, at ~108 clones each. Although degenerate primers provide a straightforward and cost-effective method for diversifying CDRs, the use of degen­erate codons limited the diversity that could be obtained at each position within the CDR and this diversity often did not exactly match the diversity seen in natural human sequences [46].
Fully Synthetic Libraries
The rst fully synthetic antibody (and fully human) library was actually a set of libraries called the Human Combinatorial Antibody Libraries (HuCAL), constructed by Knappik etal. [59] using the trinucleotide phosphoramidite method (also known
Fig. 3.3 Semi-synthetic libraries created by NNK
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Fig. 3.4 High-diversity antibody libraries created by overlap PCR
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as trinucleotide-directed mutagenesis [TRIM]). Instead of using PCR to diversify CDR3, Knappik et al. [59] sourced diversity from oligos synthesized from tri­nucleotide phosphoramidites. The nal libraries were generated by stitching together synthetic oligos by overlap-extension PCR (Fig.3.4). Although the original HuCAL design diversied only HCDR3 and LCDR3, a later iteration (HuCAL GOLD) synthetically diversied all six CDRs [60]. HuCAL and HuCAL GOLD comprised 2×109 and 3.6×1010 clones, respectively. HuCAL and HuCAL GOLD are commercially available for antibody discovery via MorphoSys AG, who devel­oped them.
Sloning BioTechnology GmbH (since acquired by MorphoSys AG) debuted a new gene synthesis strategy—a ligation-based technology called Slonomics—in 2008 [61], providing a new method for antibody library construction. The method uses a set of common building blocks to synthesize DNA sequences three nucleo­tides at a time by iterating a series of ligation, immobilization, and cleavage steps. The rst library generated by this approach, a Fab library, was as massive as HuCAL GOLD (3.6×1010) and exhibited more favorable expression in phages than other, similarly diverse synthetic libraries [62]. Compared to the synthetic diversication methods that preceded it, Slonomics offers more control over the amino acid com­position at each residue position while avoiding the introduction of PCR-related errors. The length of gene fragments synthesized by this method, however, is capped at 462bp. Gene synthesis occurs in parallel using 96-well plates.
Innovations in microarray-based gene synthesis and antibody library technolo­gies have converged to enable the construction of fully synthetic antibody libraries at unprecedented scales. Twist Biopharma, a division of Twist Bioscience, has capi­talized on the massive throughput of the Twist synthesis platform to create the larg­est collection of fully synthetic antibody libraries to date, totaling 15 distinct libraries of ~1010 size each, with more libraries on the horizon. Collectively, these libraries span multiple antibody formats (scFv, Fab, VHH), diversication strate­gies, and target classes, providing rich sources of unique antibodies for antibody drug development.
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3.5 Perspectives

Modern gene synthesis platforms have ushered in a new era of biopharmaceutical development by enabling the construction of unprecedented antibody libraries. Our goal in writing this chapter was not to comprehensively review the development of gene synthesis and antibody screening technologies. For those interested, many such reviews have been cited within this chapter. Rather, our goal was to describe how select technological achievements led to the expansion of the biopharmaceuti­cal discovery process to its current scale. The methods that contributed to the rst successes in biopharmaceutical development have been superseded by arguably superior and denitively more expansive technologies.
Recently, the combination of gene synthesis, automated experimentation, and faster and cheaper sequencing technologies has led many in the eld to take advan­tage of machine learning to generate discoveries from ever-growing datasets. In one example, Mason and colleagues [63] developed a neural network from library screening and site-directed deep-sequencing data obtained from mammalian cells. They subsequently used this model to predict the specicity of trastuzumab variants to human epidermal growth factor receptor 2 (HER2). By narrowing down the origi­nal unltered antibody library to HER2-specic binders, Mason etal. were able to greatly reduce the cost of antibody screening while generating a more successful library. The success of this approach bodes well for the marriage of computational and gene synthesis techniques in antibody discovery, a combination we believe offers nearly limitless potential. We believe the continued co-development of these technologies will spur a renaissance in biopharmaceutical discovery.
Still, there is much to learn when it comes to gene synthesis and antibody discov­ery. High secondary structure, repetitive sequences, and unknowingly toxic sequences continue to complicate the fabrication of genetic parts for discovery workows [13]. Moreover, our ability to generate antibodies of diverse formats, specicities, and naturalnesses has outstripped our ability to understand how these new engineered biomolecules behave in complex biological systems such as the human body. Developability—ensuring that antibody candidates meet basic require­ments for clinical utility, including expression, stability, and solubility—also remains a challenge, albeit one that has been partially addressed by the advent of synthetic antibody libraries. Moving forward, biopharma will need to leverage insights gained from the latest synthetic antibody libraries to inform the develop­ment of the next generation of antibody therapeutics.

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