TESSA® Platform Optimization For AAV Manufacture Efficiency

By Chloe Fustinoni, F Bennett, Mohine Alam, Danuta Lisiecka, Amy Lennon, Adam Dooner, Daniel Chow, Robert Leydon, Louise Montgomery, Weiheng Su

Scalable and efficient adeno-associated virus (AAV) manufacturing remains a central challenge in meeting the growing demand for gene therapies worldwide. With the increasing number of clinical programs advancing toward commercialization, biopharmaceutical developers are seeking more robust, reproducible, and cost-effective production strategies. Recent innovations in vector manufacturing are addressing these needs by improving yield, purity, and scalability without compromising product quality.

Advances in helper technologies, cell-line engineering, and process optimization have led to significant gains in both productivity and consistency. Enhanced expression control and refined production workflows now enable more efficient genome packaging and higher proportions of full capsids, contributing to improved therapeutic performance. In parallel, analytical tools such as next-generation sequencing, mass photometry, and advanced process monitoring support a deeper understanding of vector quality and process performance.

Together, these developments are transforming the landscape of AAV production. By reducing manufacturing complexity and cost of goods, next-generation methods are making gene therapy manufacturing more accessible, reliable, and scalable, helping accelerate the delivery of safe, effective treatments to patients worldwide.