Optimizing VLP Manufacturing For Gene Editing By GMP-Compliant Flow Electroporation®

Gene editing using virus-like particles (VLPs) is a promising strategy for delivering therapeutic payloads, but scaling up production can be challenging. Manufacturing VLPs often involves multiple optimization rounds to transition from research to clinical scale, and traditional chemical methods can lead to inconsistent batches.

This presentation explores a workflow using flow electroporation to produce VLPs in both adherent and suspension HEK cells. The approach consistently achieves high yields of functional VLPs that can deliver CRISPR-Cas9 or adenine base editor RNPs for efficient gene editing in primary human cells. Additionally, this method significantly reduces the manufacturing timeline to a single day and offers a scalable solution, enabling a 400-fold increase in production volume with minimal re-optimization.