AAV Process Development in Culture Biosciences’ 250mL Bioreactors

Adeno-associated viruses (AAVs) are widely used as delivery vehicles in gene therapy. Yet, optimizing AAV process development remains a challenge with the high cost of scaling up manufacturing and AAV vector production complexities. The AAV production process is sensitive to upstream and downstream variabilities, which means standardization is difficult across different AAV vector plasmids and serotypes.

Using AAV triple transfection in suspension HEK293 cells can yield viral genome titers exceeding 1x10¹⁴ genomes/L. And despite the potential of AAV vector genome titers and the percentage of filled capsids to vary widely across batches, requiring precise adjustments, even small changes, such as switching plasmids or transfection reagents, can lead to order-of-magnitude differences in viral titers, necessitating AAV cell line development and process optimization critical.

By leveraging small-scale bioreactors for process optimization, you can efficiently test and refine conditions that drive robust AAV viral vector development. At Culture Biosciences, we have proven how running multiple 250mL bioreactors for viral vector production in parallel allows for rapid identification of transfection reagents, complexation conditions, and process parameters that improve overall AAV vector production efficiency.

Want to dive deeper into strategies for optimizing AAV vector genome titers and streamlining your AAV production process? Download our detailed whitepaper to explore how small-scale bioreactor platforms can enhance reproducibility and scalability in AAV viral vector manufacturing.

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