I use suspension HEK293 [GnT1-] cells for large scale (>5L) expression of mammalian membrane proteins. My goal is to consistently have "crystallization yields" of protein. Right now I'm quite happy with my yield (~1mg/L of crude fusion protein, 0.1-0.3mg/L of final purified protein - don't laugh, we're talking about eukaryotic membrane proteins here!!) But my transient transfection protocol is quite laborious (and costly). 

I'm using 25kD linear PEI to form in situ DNA:PEI complexes (based on work from the Wurm group, see link). The problem is that this method requires a very high density of cells (~20 x 10^6 cells/ml), which becomes a huge pain when dealing with sterile concentration of multiple liters of cells (via centrifugation and resuspension). Additionally, the excessive amounts of expensive media seems unnecessarily wasteful.

Instead of the high-density technique, I am getting increasingly interested in using preformed PEI-DNA complexes, thus obviating the need to excessively concentrate the cells prior to transfection. The problem is that, in my hands, expression is >10-fold lower using this method, despite varying the incubation time, PEI:DNA ratio, pH, etc etc...

Any advice for increasing my transfection efficiency using the preformed-complex technique? What is your secret sauce???

http://onlinelibrary.wiley.com/doi/10.1002/bit.21596/abstract

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