To 1000L and beyond: streamlining AAV manufacturing with transfection complex stabilization

Live30 webinars are thirty-minute presentations designed to update you on the latest innovations, applications, and data in a fast yet interactive format.

Unlock easier, more efficient AAV manufacturing scale-up with a novel approach to transfection. This webinar introduces an approach designed to help process development and manufacturing teams overcome two key limitations during scale-up: short transfection complex stability and the high volume of transfection reagents required at large scale. Attendees will gain insights into how extending the usable window of transfection complexes from minutes to hours can dramatically increase operational flexibility, especially in larger production runs where timing and coordination are crucial.

By decoupling the preparation of transfection complexes from their immediate use, this approach allows for more controlled, predictable, and resource-efficient upstream workflows. Additionally, this approach enables a significant reduction in the volume of transfection complexes required—from the standard 5% to 2% of total culture volume. This in turn, results in a reduced material burden, reduced costs, and simpler handling at the production scale, all while maintaining high AAV titers.

The webinar will also feature a real-world case study from Forge Biologics, highlighting how this method was used to streamline and scale AAV production up to 1000L. The speakers will show how implementing this transfection complex stabilizer helped eliminate timing bottlenecks, reduce complexity, and maintain yield consistency throughout the process.

Attend this webinar to:

• Gain insights into integrating transfection complex stabilization into existing workflows to improve process robustness
• Discover how reducing transfection complex volume from 5% to 2% of total culture volume can cut material use, lower handling burden, and streamline large-scale AAV production workflows
• Learn about a real-world case study that implemented transfection complex stabilization to successfully scale AAV manufacturing to 1000L while maintaining consistent yields and simplifying process execution
• Explore how transfection complex stabilization helps de-risk scale-up by minimizing time-sensitive steps and enabling more predictable, repeatable upstream performance across production runs

Leisha Kopp

Senior Field Applications Scientist at Mirus Bio

Leisha Kopp is a Senior Field Applications Scientist at Mirus Bio, a company committed to equipping biopharmaceutical innovators with next generation transfection solutions for all cell culture applications. Leisha has 20 years of molecular biology and mammalian cell culture experience in industrial labs and has worked extensively with an array of primary and immortalized mammalian cells. Her combined bench and biopharma knowledge enables support of scientists in all stages of the drug discovery process to develop optimized and scalable processes that deliver complex therapies to patients more quickly. Leisha is a graduate of the University of Wisconsin-Madison, with key interests in viral vector manufacturing and gene therapy.

Mason Bonitz

Senior Scientist, Process Development at Forge Biologics

Mason Bonitz is a Senior Scientist on the Process Development team at Forge Biologics, a CDMO that offers high-yield AAV manufacturing, a world-class cGMP facility, and seamless support from concept to commercial. Mason has 7 years of Process Development experience, primarily focusing on bioreactor scale-up and AAV transfection optimization. He has participated in bringing multiple therapeutic products from small-scale screening studies to large-scale manufacturing, leveraging his experience in process optimization and scale-up. Mason is a graduate of the Ohio State University, with a focus in Biology.

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SPEAKERS

Leisha Kopp

Senior Field Applications Scientist at Mirus Bio

Mason Bonitz

Senior Scientist, Process Development at Forge Biologics

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