Scaling AAV Manufacturing To 1000 L: Strategies For Robust And Reproducible Production

Scaling adeno-associated virus (AAV) production requires more than transferring a process into a larger bioreactor. Cell line, media, and process design must work together to maintain productivity, consistency, and product quality as volumes increase. An integrated approach to transient AAV production can support reliable performance from early development through commercial manufacturing. Scale-up data illustrate critical process parameters, key scalability considerations, and strategies for reducing variability at larger volumes. A real-world case study developed with MilliporeSigma’s viral vector CDMO demonstrates implementation of an AAV process using the ELEVECTA™ transient cell line at 1000 L scale, showing how thoughtful process development and scalable technologies can deliver manufacturing-ready performance.

Watch to learn practical strategies for de-risking AAV scale-up and accelerating the path to large-scale production.