I have read some papers concerning expression levels of proteins and instances of misfolding to due to "back up" during cellular processing.
I am expressing viral surface proteins and derived constructs in vitro in both 293F and Expicho. It is quite often that we will design a new construct and after purifcation, see that there is quite significant aggregation, and/or deleterious bands on the SDS-page. We often attribute this to a poor design. How likely is it that the protein is being overexpressed, causing the misfolding and aggregation? We typically add 900ug plasmid DNA per liter of transfection for 293F, and 1000ug per liter of Expicho.