Lentiviral vectors (LVs) have emerged as a cornerstone of gene therapy, enabling transformative treatments ranging from ex vivo applications like CAR T  to promising in vivo delivery approaches. Yet, despite their potential, LV production remains one of the most complex and resource-intensive challenges in advanced therapy manufacturing. High costs, variable yields, and sensitivity to production conditions continue to slow the path to commercialization.

A Scalable Solution: Fixed-Bed Bioreactors

To overcome these obstacles, manufacturers are increasingly turning to fixed-bed bioreactor technologies like the scale-X™ platform. By providing a homogeneous, low-shear environment, these systems protect cells during production and create conditions that support higher productivity and product stability.

Key advantages of the scale-X approach include:

• Linear scalability from R&D (0.5 m²) to commercial-scale production (600 m²).

• Continuous vector collection, which improves yield consistency and reduces product degradation.

• Cleaner harvests, resulting in fewer impurities and reduced downstream processing burden.

The result is a measurable increase in productivity coupled with a lower cost of goods (COGS) per dose—critical drivers in making cell and gene therapies more accessible to patients.

From Lab Bench to Commercial Scale

The scale-X portfolio covers the full spectrum of development, from discovery-stage research to mid- and large-scale manufacturing. By reducing operating footprint and optimizing labor, material, and facility costs, the platform not only accelerates process development but also supports commercial viability.

Higher viral yields per run, improved product consistency, and reduced overall costs translate into greater confidence for therapy developers and a clearer path toward industrialization.

Explore the Infographic: For a visual breakdown of LV production challenges and the benefits of the scale-X™ platform, see the infographic above“Optimizing Lentivirus Production Using Fixed-Bed Bioreactors”.