I precede these answers with the statement that I personally have not used the ionworks HT but am very familiar with the machine and work in a lab the specializes in conventional patch electrophysiology
I doubt your problem it is due to low channel expression. In general I have found non-transfected cells usually give the high seal resistances. If you want to check your channel expression levels, just pop a few on a conventional rig and do some whole cell experiments.
What cell lines are you using and what channels are you expressing?
How are you dissociating the cell from culture flask and putting them in solution for patch? You will want to avoid trypsinization and use at most an enzyme free dissociation cocktail, or just mechanically dissociate the cells with a cell scraper or bashing a flask to preserve membrane integrity. HEK293 cells in particular do not like enzymatic dissociation.
In general, try to avoid using cells more than 15 passages after thawing because their morphology (and cell size) can change dramatically after that. Furthermore if you are using a stably expressing line you should be careful that the cell line does not "spit out" the stably transfected channel or one of its subunits after 12 or so passages (Ive had this happen with calcium channel subunits while the cell still retains the antibiotic resistance cassette).
To improve seal quality you can make your intracellular solution have a lower osmolarity compared to the extracellular solution by about 10%. This encourages the cell to swell slightly and form a tighter seal with the chip before you perforate. Additionally you should try and match the osmolarity of your extracellular solution to the culture media in which the cell grew so that they do not swell or shrink too much during the preparation for patching.
Do you use amphotericin free intracellular solution while you attain your seals and then switch to solution with the perforant? If you have amphotercin in the intracellular solution while you are trying to get your seal it may be that you are not forming your seal fast enough and amphotericin is getting into both intracellular and extracellular solutions and completely perforating many of your cells resulting in extremely poor seals.
You may also want to read some of the technical tips from the Molecular Devices web site:
Eg. Increased seal resistance by placing Patch Plates in a dessicator
http://www.moleculardevices.com/pdfs/IonWorks_Technical_Tip_1.pdfOther technical tips are at
http://www.moleculardevices.com/product_literature/family_links.php?familyid=10I hope Ive been some help. Let us know how you fixed you problem even if it is not any of my suggestions because it will be useful for other people in a similar position to yourself. Good luck.