Cost Modeling Analysis Of AAV And LV Manufacturing With iCELLis™ 50 Fixed-Bed Bioreactor

By F. Saltarin, S. Krekels, E. Cameau, and A. Laskowski

As viral vector programs move from development into clinical and early commercial stages, manufacturing decisions can have an outsized impact on cost, timelines, and facility requirements. This poster explores how manufacturing scale influences the economics of adeno-associated virus (AAV) and lentiviral (LV) production, using realistic scenarios for gene therapy and CAR T applications. By modeling upstream and downstream operations, consumables, labor, capital investment, and facility footprint, it highlights where costs accumulate and where they can be reduced. The findings show how an intermediate manufacturing scale can support process development, validation, and medium-sized clinical batches while lowering capital outlay and operational complexity.

See how different manufacturing scales compare across real-world AAV and LV scenarios.