AAV Manufacturing: Innovative Technology for Scalable, Plasmid-Free Production

Adeno-associated viral vectors (AAV vectors) are essential tools for delivering gene therapy to patients and are usually manufactured using plasmid-based approaches. However, there are challenges with working with plasmids on a large scale, including consistency and scalability. In addition, manufacturing approaches must keep pace with the rapid scientific advances in the gene therapy field to meet the demands for high and consistent yields of AAV. Recently published data demonstrated that plasmid-free technology could produce over tenfold more AAV compared with a transient approach and particles which are 5- to 60-fold more infectious—which represents a scalable approach to AAV manufacturing.

In this GEN webinar, we will hear detailed information about the recent design of experiments studies to optimize a process for large-scale AAV manufacture using TESSA™ technology, When scaled up to 200 L, TESSA produced 30 to 40 times more AAV than triple transfection, with around 95% full capsids. AAV titer, quality, and infectivity stayed consistent at scale, demonstrating the robustness of our process for AAV manufacture.

A live Q&A followed the presentation, offering a chance to pose questions to our expert panelists.