Cell‐free synthesis and maturation of [FeFe] hydrogenases

[FeFe] hydrogenases catalyze the reversible reduction of protons to molecular hydrogen (Adams (1990); Biochim Biophys Acta 1020(2): 115–145) and are of significant interest for the biological production of hydrogen fuel. They are complex proteins with active sites containing iron, sulfur, and carbon monoxide and cyanide ligands (Peters et al. (1998); Science 282(5395): 1853–1858). Maturation enzymes for [FeFe] hydrogenases have been identified (Posewitz et al. (2004); J Biol Chem 279(24): 25711–25720), but complete mechanisms have not yet been elucidated. The study of [FeFe] hydrogenases has been impeded by the lack of an easily manipulated expression/activation system capable of producing these complex and extremely oxygen‐sensitive enzymes. Here we show the first expression of functional [FeFe] hydrogenases in an Escherichia coli ‐based cell‐free transcription/translation system. We have produced and matured both algal and bacterial hydrogenases using E. coli cell extracts containing the HydG, HydE, and HydF proteins from Shewanella oneidensis . The current system produces ∼22 µg/mL of active protein, constituting ∼44% of the total protein produced. Active protein yield is greatly enhanced by pre‐incubation of the maturation enzyme‐containing extract with inorganic iron and sulfur for reconstitution of the [Fe‐S] clusters in HydG, HydE, and HydF. The absence of cell walls permits direct addition of cofactors and substrates, enabling rapid production of active protein and providing control over the maturation conditions. These new capabilities will enhance the investigation of complex proteins requiring helper proteins for maturation and move us closer to the development of improved hydrogenases for biological production of hydrogen as a clean, renewable alternative fuel. Biotechnol. Bioeng. 2008;99: 59–67. © 2007 Wiley Periodicals, Inc.