It is generally assumed that in proteins hydrophobic residues are not favorable at solvent-exposed sites, and that amino acid substitutions on the surface have little effect on protein thermostability. Contrary to these assumptions, we have identified hyperthermostable variants of Bacillus licheniformis ␣-amylase (BLA) that result from the incorporation of hydrophobic residues at the surface. Under highly destabilizing conditions, a variant combining five stabilizing mutations unfolds 32 times more slowly and at a temperature 13°C higher than the wild-type. Crystal structure analysis at 1.7 Å resolution suggests that stabilization is achieved through (a) extension of the concept of increased hydrophobic packing, usually applied to cavities, to surface indentations, (b) introduction of favorable aromatic-aromatic interactions on the surface, (c) specific stabilization of intrinsic metal binding sites, and (d) stabilization of a -sheet by introducing a residue with high -sheet forming propensity. All mutated residues are involved in forming complex, cooperative interaction networks that extend from the interior of the protein to its surface and which may therefore constitute "weak points" where BLA unfolding is initiated. This might explain the unexpectedly large effect induced by some of the substitutions on the kinetic stability of BLA. Our study shows that substantial protein stabilization can be achieved by stabilizing surface positions that participate in underlying cooperatively formed substructures. At such positions, even the apparently thermodynamically unfavorable introduction of hydrophobic residues should be explored.Some general rules for increasing the stability of proteins have been derived from a large number of comparative structural and mutagenesis studies (1, 2). Among the most generally recognized strategies for protein thermostabilization are: increasing the hydrophobic packing in the interior, decreasing surface hydrophobicity, extending networks of salt-bridges and hydrogen bonds, engineering disulfide bonds or metal binding sites, shortening or strengthening solvent-exposed loops and termini, increasing the extent of secondary structure formation, and replacing residues responsible for irreversible chemical alterations of the protein structure. Yet, these general rules may not always be applied successfully and examples of engineered mutations resulting in effects opposite to the ones expected are legions. Such studies have also failed to reveal outstanding features associated with the adaptation of proteins to a given temperature range, i.e. psychrophilicity, mesophilicity, thermophilicity, and hyperthermophilicity. While most natural proteins seem to achieve their respective stability by accumulating a large number of weakly stabilizing interactions that result in a large net effect, some have acquired specialized structural features that cannot easily be transferred in a general way into other proteins (3, 4). Elucidating the origin of thermal stability for a given protein and finding ...