Exploring nutrient supplementation and bioprocess optimization to improve the production of lentiviral vectors in serum‐free medium suspension cultures

Abstract The use of lentiviral vectors (LV) in gene therapy has been growing in recent years. To meet the increasing clinical demand, LV production platforms will benefit from improved productivity and scalability to enable cost‐effective manufacture of LV‐based therapies. Here we report the adaptation of 293T cells to serum‐free suspension cultures and the improvement of LV yields through transfection parameters optimization, process intensification and medium supplementation with nutrient boosters. Cells were sequentially adapted to different serum‐free culture media, transfection parameters were optimized and the two best‐performing conditions were selected to explore process intensification by increasing cell density at the time of transfection. LV production at higher cell densities increased volumetric titers up to 12‐fold and lipid supplementation was the most efficient metabolic optimization strategy further enhancing LV productivity by 3‐fold. Furthermore, cell concentration was identified and validated as an important source of transfection variability impairing cellular uptake of DNA polyplexes, impacting transfection efficiency and reducing LV titers down to 6‐fold. This work contributes to improving LV‐based gene therapy by establishing new scalable manufacturing platforms and providing key metabolic insights, unveiling important bioreaction parameters to improve vector yields.