Commercial viral vector manufacturing: Current and future state, challenges and opportunities


With several recent FDA approvals and a strong drug pipeline, the gene therapy market is providing new hope for patients. As demand for these new therapies increases, a robust and scalable manufacturing process is critical. We will address how to mitigate the risk of contamination by adventitious agents to ensure viral vector safety used in biotherapeutics. One of the first steps in designing a process is whether to use adherent or suspension cell cultures.  Each modality has its advantages and disadvantages. This presentation will outline the key considerations in choosing the right technology and some of the pitfalls that must be overcome to ensure success at large scale will be discussed.


We will present three case studies which illustrate the strategies for viral vector manufacturing production. The first case study will demonstrate the production of lentivirus in a fixed bed bioreactor, resulting in a 1.62-fold increase in the average titer (TU/cm2). The second case study will show data regarding the development of AAV9 production in adherent HEK293 cells, utilizing the iCELLis® Nano Bioreactor. Based on conditions developed in this bench-top iCELLis Nano, we scaled production to the fully closed, single-use Xpansion® 200 Multiplate Bioreactor for seed train and the production-scale iCELLis 500 single use bioreactor. Following a production phase, >1016 vector genomes were isolated from crude harvest of the bioreactor.  The last case study will demonstrate scalability of AAV production in suspension HEK293 cells from the AllegroTM STR 50 Bioreactor to the Allegro STR 500 Bioreactor, while achieving similar product yield and quality. 


Rachel Legmann, PhD




Commercial viral vector manufacturing: Current and future state, challenges and opportunities

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The Cell Culture Dish have partnered with industry experts Pall Biotech, Cobra Biologics, SCIEX, REGENXBIO Inc., BioTechLogic and Jane Barlow & Associates, LLC to share their perspectives in a new ebook, 'Insights on Successful Gene Therapy Manufacturing and Commercialization'.

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May 2021
Overcome Exosome Production Challenges

Biotech | Pall Corporation webinar series

This webinar was recorded by BioPharma Asia and first published on their website. It is made available here by kind permission of BioPharma Asia and the presenters. Scroll down to see a transcript of the webinar question and answer session.


Hailed as the “next frontier” in cell therapy and regenerative medicine, exosomes are a type of extracellular vesicle and play a key role in the regulation of the intercellular communication processes.

David Haylock of VivaZome will present on upstream production of angiogenic exosomes using the iCELLis® nano fixed bed bioreactor. This will be followed by a presentation by Roberto Ciboldi of Pall Corporation on a platform solution including cell culture, purification and sterile filtration of exosomes.

Participants will be able to:


  • Compare the performance of the iCELLis Nano bioreactor to traditional flasks for exosome production from adherent cell culture
  • Understand how an integrated end to end platform delivers highly   purified and consistently-sized exosomes
  • Discover an innovative cGMP scalable manufacturing platform for   exosomes