An FAD-dependent glucose dehydrogenase (FAD-GDH) from Aspergillus terreus NIH2624 was expressed in Escherichia coli With a yield of 228 +/- 16 U/L of culture. Co-expression with chaperones DnaK/DnaJ/GrpE and osmotic stress induced by simple carbon, sources enhanced productivity significantly, improving the yield to 23883 +/- 563 U/L after optimization. FAD-GDH was purified in two steps with the specific activity of 604 U/mg. Using D-glucose as substrate, the optimal pH and temperature for FAD-GDH were determined to be 7.5 and 50 degrees C, respectively. Activity was stable across the pH range 3.5-9.0, and the half-life was 52 min at 42 degrees C. K-m and V-max were calculated as 86.7 +/- 5.3 mM and 928 +/- 35 U/mg, and the molecular weight was approximately 65.6 kDa based on size exclusion chromatography, indicating a monomeric structure. The 3D structure of FAD-GDH was simulated by homology modelling using the structure of A. niger glucose oxidase (GOD) as template. From the model, His551, His508, Asn506 and Arg504 were identified as key residues, and their importance was verified by site-directed mutagenesis. Furthermore, three additional mutants (Arg84Ala, Tyr340Phe and Tyr406Phe) were generated and all exhibited a higher degree of substrate specificity than the native enzyme. These results extend our understanding of the structure and function of FAD-GDH, and could assist potential commercial applications. (C) 2014 Elsevier Inc. All rights reserved.