Cutting CAR-T manufacturing costs: a systematic approach to enhancing lentiviral transduction efficiency

Viral vector costs represent a critical barrier to affordable and consistent CAR-T cell therapy manufacturing. Despite this challenge, transduction processes lack systematic optimization of the physical and chemical parameters that drive efficient gene transfer.

In this webinar, our guest speaker presents a comprehensive Quality-by-Design (QbD) framework that has been applied to CAR-T transduction to achieve a 2–3x improvement in efficiency. This approach can directly reduce viral vector requirements and manufacturing costs. By systematically optimizing physical and chemical parameters, the framework identifies key drivers of transduction, including LentiBOOST™ enhancer, and provides a scalable, serum-free strategy with strong translational potential.

In this webinar, you will learn:

• Practical strategies to reduce viral vector consumption.
• A transferable QbD framework applicable across manufacturing platforms.
• Critical considerations for accurate titer determination using primary cells.
• Translation pathway from research-grade to clinical-grade serum-free conditions.
• A data-driven approach to reduce manufacturing costs, improve process consistency, and support broader access to CAR-T therapies.

Register to watch on-demand.

Speaker:
Dr. Pedro Silva Couto
Assistant Professor, Chemical Engineering, University of Bath

Pedro Silva Couto is a lecturer in Chemical Engineering at the University of Bath, where his research focuses on cell and gene therapy manufacturing. His work applies process engineering and Quality-by-Design principles to develop scalable bioprocesses gene delivery and cell manufacturing, with applications including CAR-T cells and hMSC expansion in stirred tank bioreactors, aiming to reduce costs and accelerate clinical translation.

LentiBOOST Pharma-Grade technology: For research use only. Not for use in diagnostic procedures.
LentiBOOST GMP Grade technology: Not for diagnostic use. Other applications must be authorized by a license from Revvity.