Viral Vector Manufacturing and Analytics Program

Mission

Develop and make broadly available a robust, economically viable, shared-access platform for the technical development, manufacturing, and characterization of AAV-based gene therapy vectors. Ensure that workforce training for this platform can integrate into existing curriculum or training models to encourage adoption, and integrate improvements into the platform based on feedback from these training programs.

Vision

A gene-based therapeutics industry capable of serving patients across the full spectrum of unmet needs—from prevalent indications to ultra-rare diseases—that has access to high-quality viral vectors without cost or speed limitations.

What are viral vectors and how will they benefit the industry?

One of the most important vector platforms in use in the biopharmaceutical industry today is adeno-associated virus (AAV) vectors. Our Program focuses on advancing the manufacturing process and analytical capabilities for AAV vectors. The advances are critical for broad and rapid expansion of the emerging industry of gene-based therapeutics and ultimately the many patients and families who can benefit from access to these novel therapies.


NIIMBL is well-positioned to bring together the right resources to accelerate development of core manufacturing process platforms and essential analytical capabilities for viral vector product and process characterization, which can

  • Ensure manufacturing platforms are flexible and robust to accelerate business objectives
  • Improve therapy yield of known manufacturing platforms
  • Reduce individual investment and resources needed to help manufacture life-improving and life-saving gene therapies 

Viral Vectors Program Structure

Program Operating Plan

Stage 1: Baseline Process (Q2 2025 - Q2 2026)

  • Establish a publicly describable baseline manufacturing process defined in terms of key unit operations.
  • Using this baseline process, produce a representative batch and communicate how it was manufactured, including process performance and product quality outcomes.
  • Build internal capability while generating awareness, support, and enthusiasm for the forthcoming NIIMBL platform.

Stage 2: NIIMBL Platform (Q4 2026 - Q4 2027)

  • Use the baseline process as the foundation to develop a robust Platform manufacturing process and accompanying analytical package and demonstrate the resulting performance capabilities.
  • Incorporate accessible GMP cell bank options within the Platform and assess its applicability across multiple AAV serotypes and transgenes.
  • Manufacture a batch using the Platform and clearly describe how it was produced, including process execution, performance, and product quality outcomes.
  • Deploy the Platform in a manner that enables access for rare disease product sponsors.

Stage 3: AAV Technology Innovation (Q4 2026 - Q4 2027)

  • Transition the NIIMBL Platform from demonstration to broad implementation by enabling its use across multiple manufacturing environments.
  • Integrate lessons learned from baseline and platform stages to refine process robustness, analytical readiness, and operational scalability.
  • Expand applicability across additional serotypes, transgenes, and emerging vector modalities as appropriate.
  • Support technology transfer activities and ensure rare‑disease product sponsors and ecosystem partners can adopt the Platform effectively.
  • Establish mechanisms for continuous feedback, performance monitoring, and iterative improvement to sustain long‑term impact.

Workstreams

The work of the program is organized around workstreams, topical focus areas.

Processes Workstream

Stage 1
  • Process definition based on publicly accessible information
  • Identify and contract CDMO for 1-3 batches (e.g., 50L including feedstocks)
  • Tech transfer and support 1st campaign CDMO development runs and share data publicly
Stage 2
  • Develop accessible GMP MCB & WCB options; evaluate multiple serotypes and transgenes
  • Develop and demonstrate upstream and downstream performance capabilities
  • Process lockdown – balancing performance and breadth of applicability
  • Tech transfer and support 2nd campaign CDMO development runs and share data
  • Develop a network of willing and capable manufacturing sites to run this process
Stage 3
  • Explore novel technologies such as (for example): Packaging/producer MCB/WCB, Sf9 access, novel affinity resins, improved full capsid enrichment
  • Explore data tools such as AI/ML-based optimization models

Analytics Workstream

Stage 1
  • Identify the minimum CQA list with corresponding methods
  • Tech transfer and support 1st campaign CDMO development runs and share data publicly. Data may be generated using proprietary technology
Stage 2
  • Determine best method for each product attribute. This may require head-to-head comparison of multiple methods.
  • Develop publicly accessible SOPs for each platform method
  • Develop in-process methods and tools
  • Tech transfer and support 2nd campaign CDMO development runs and share data
Stage 3
  • Design alternative sample-sparing methods
  • Develop robust and repeatable rcAAV method
  • Standardize and simplify Next-Gen Sequencing (NGS)
  • Develop in vitro potency standards

Translational Network Workstream

Scope

The Translational Network Team (TNT), a core workstream within NIIMBL’s Viral Vector program, was established to align scientific innovation with the practical needs of rare and ultra-rare disease communities. TNT begins by identifying areas of highest unmet need and analyzing market trends to guide strategic focus and anticipate shifts in the gene therapy landscape. By characterizing key stakeholders, including patients, caregivers, clinicians, and advocacy groups, the team ensures that development efforts are informed by a clear understanding of who will benefit most. A major initiative within TNT is the creation of a distributed Viral Vector testbed, enabling researchers to bring rare disease vectors into larger-scale production environments. This infrastructure supports broader access to manufacturing capabilities and accelerates the translation of promising therapies.

Progress and updates

Program Participants

NIIMBL Program Co-leads

Eric Hacheri, Co-Lead Viral Vectors Program

Eric Hacherl

NIIMBL Senior Fellow
Chris Williams

Chris Williams

Viral Vector Program Co-lead

Program Advisor

Tim Charlebois, Senior Fellow

Tim Charlebois

NIIMBL Senior Fellow

NIIMBL Scientific Program Manager

Angie Snell Bennett

Scientific Project Manager

Alexion Pharmaceuticals

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