Researchers at the Lawrence Livermore National Laboratory (LLNL) have created a new type of bioreactor that transforms waste methane into succinate, a chemical widely used in industries like pharmaceuticals and plastics. Published in Scientific Reports, this innovation uses 3D-printed structures to enhance the efficiency of methane conversion, outperforming traditional methods by more than 10 times while using less energy. The system relies on methanotrophs, a type of bacteria that naturally consumes methane. Unlike conventional chemical processes that require heat or pressure, these microbes work under mild conditions, reducing costs and energy use. Instead of using large liquid-filled tanks, the new bioreactor uses 3D-printed, lattice-like scaffolds filled with hydrogel. This hydrogel contains the bacteria and allows methane gas to reach them quickly, without needing to dissolve the gas in liquid or mechanically stir the mixture. LLNL’s advanced 3D printing technology allowed the team to combine materials, printing techniques, and design elements into a unified development process. This approach enabled the rapid creation of reactor prototypes in various sizes, speeding up the shift from design to testing and scaling up the technology. One of the main challenges was balancing the engineering of the reactor with the biological needs of the bacteria. The team had to design the scaffolds to support high cell density and efficient gas interaction while keeping the microbes alive for extended periods. Starting with a small 2-milliliter reactor, they scaled up to a 1-liter version, but further development is needed for large-scale applications. The compact design could be particularly useful for smaller facilities like landfills or wastewater treatment plants, which often lack efficient methane processing solutions. Additionally, the scaffold structure might be adapted for other biochemical processes, potentially improving oxygen delivery and eliminating the need to separate catalysts after reactions.