The Race to Reinvent AAV Manufacturing Gains New Fuel

VintaBio’s high yield AAV data points to faster, scalable manufacturing, giving early adopters a potential edge as demand accelerates

16 May 2025

VintaBio’s latest manufacturing data have intensified interest in new methods for producing adeno-associated viral vectors, a core component of gene therapies. Findings presented at ASGCT 2025 indicate higher yields and fewer defective particles, giving developers cautious optimism as demand for vectors increases.

The company’s platform introduces an assembly method designed to give AAV particles more time to form correctly. According to VintaBio’s ASGCT 2025 release, recent batches contained more than 50 per cent full capsids at harvest, alongside higher viral genome counts than earlier benchmarks. The data suggest a reduction in empty capsids, which have long slowed output and increased the burden on downstream purification. No public cost-per-dose figures have been disclosed, leaving the financial impact uncertain.

Regulators have not yet endorsed the process. Methods are still under review, and agencies are expected to test performance at multiple scales before approving any shift from existing standards. One regulatory adviser said that “higher yields are promising, but agencies will require proof of consistency and reproducibility across multiple scales before approving any manufacturing change”.

Sector analysts note that a rise in functional particles could streamline purification and, over time, lower overall production costs. Such benefits would be significant as gene therapy developers move from rare disease programmes to larger treatment areas. For now, any cost savings remain speculative.

In parallel, ProteoNic is advancing expression-enhancing technology aimed at increasing how much viral material cells can generate in early production steps. Reviewers see potential for this to complement VintaBio’s assembly approach, offering combined gains in usable vector yield.

Both developments point to a shift towards more predictable gene therapy manufacturing. Validation studies due in the coming months will determine how far the early results can be replicated. Developers that adopt the methods ahead of regulatory guidance may gain an advantage, but widespread uptake will depend on formal acceptance of new manufacturing standards.