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Predaking, the last living Predacon, was captured by Shockwave, who was given the green light by Megatron to start the project. The goal was to create a unit of Decepticon warriors who took on powerful beast modes derived from Predaking's CNA. The project was filed as Top Secret, and only Shockwave and Megatron knew about it.

In order to prevent heavy casualties among Decepticon ranks, Autobot captives and prisoners of war were used as test subjects. It took several centuries for the Autobots to finally learn about the project and where their missing brothers and sisters had disappeared to. As soon as Optimus heard about it and acquired all necessary details as to where the experiments were being conducted, he set out to liberate the captives himself.

Unfortunately, things went south pretty fast. Most of the captives used as test subjects did not survive the process, so the mission became more of a retrieval than a rescue. Optimus refused to leave Shockwave's lab until he knew everyone - dead or alive - was freed, and the lab destroyed. The cost was him getting accidentally infected with one of Shockwave's most recent doses of Predacon CNA before blowing up the rest of the lab.

Back at the Autobot base, those who were able to be saved were in poor shape, and even fewer survived the healing process (something that still weighs quite heavily on Ratchet's mind). Those that made it out alive were now permanently stuck as beasts, having lost their ability to transform during Shockwave's various experiments (most likely their t-cogs had been disabled to minimize interference with the CNA tests). These survivors formed their own faction, the Maximals, and allied themselves with the Autobots.

In typical fashion, Optimus did not allow himself to be treated until Ratchet confirmed that everyone else was alright first. This led to the Predacon CNA setting within his internal systems, giving him an accidental beast mode, but because the experimental vial was unfinished it caused this mode to be violently unstable. An initial transformation wouldn't do any harm, but the longer he remained in Predacon form, the more feral and violent he would become, like a wild animal. Optimus swore to never be a beast unless absolutely necessary, and in case he ever lost it he and Ratchet formed a contingency plan (in other words, I needed something to balance the power curve).

As for Predaking, he was able to earn his freedom back by proving himself in battle against Megatron himself. Megatron may be a warlord, but he still lives by Gladiatorial Code, and allowed Predaking to be released, thus ending Project: Predacon for good. Predaking remains a neutral party, wanting nothing to do with the Decepticons or the war.

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