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Marwidi Y, Nguyen HOB, Santos D, Wangzor T, Bhardwaj S, Ernie G, Prawdzik G, Lew G, Shivak D, Trias M, Padilla J, Tran H, Meyer K, Surosky R, Ward AM. A robust and flexible baculovirus-insect cell system for AAV vector production with improved yield, capsid ratios and potency. Mol Ther Methods Clin Dev 2024; 32:101228. [PMID: 38524756 PMCID: PMC10959708 DOI: 10.1016/j.omtm.2024.101228] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 02/09/2024] [Accepted: 02/28/2024] [Indexed: 03/26/2024]
Abstract
Manufacturing of adeno-associated viruses (AAV) for gene and cell therapy applications has increased significantly and spurred development of improved mammalian and insect cell-based production systems. We developed a baculovirus-based insect cell production system-the SGMO Helper-with a novel gene architecture and greater flexibility to modulate the expression level and content of individual Rep and Cap proteins. In addition, we incorporated modifications to the AAV6 capsid sequence that improves yield, capsid integrity, and potency. Production of recombinant AAV 6 (rAAV6) using the SGMO Helper had improved yields compared to the Bac-RepCap helper from the Kotin lab. SGMO Helper-derived rAAV6 is resistant to a previously described proteolytic cleavage unique to baculovirus-insect cell production systems and has improved capsid ratios and potency, in vitro and in vivo, compared with rAAV6 produced using Bac-RepCap. Next-generation sequencing sequence analysis demonstrated that the SGMO Helper is stable over six serial passages and rAAV6 capsids contain comparable amounts of non-vector genome DNA as rAAV6 produced using Bac-RepCap. AAV production using the SGMO Helper is scalable using bioreactors and has improved yield, capsid ratio, and in vitro potency. Our studies demonstrate that the SGMO Helper is an improved platform for AAV manufacturing to enable delivery of cutting-edge gene and cell therapies.
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Affiliation(s)
- Yoko Marwidi
- Sangamo Therapeutics, 501 Canal Boulevard, Richmond, CA 94804, USA
| | | | - David Santos
- Sangamo Therapeutics, 501 Canal Boulevard, Richmond, CA 94804, USA
| | - Tenzin Wangzor
- Sangamo Therapeutics, 501 Canal Boulevard, Richmond, CA 94804, USA
| | - Sumita Bhardwaj
- Sangamo Therapeutics, 501 Canal Boulevard, Richmond, CA 94804, USA
| | - Gabriel Ernie
- Sangamo Therapeutics, 501 Canal Boulevard, Richmond, CA 94804, USA
| | - Gregg Prawdzik
- Sangamo Therapeutics, 501 Canal Boulevard, Richmond, CA 94804, USA
| | - Garrett Lew
- Sangamo Therapeutics, 501 Canal Boulevard, Richmond, CA 94804, USA
| | - David Shivak
- Sangamo Therapeutics, 501 Canal Boulevard, Richmond, CA 94804, USA
| | - Michael Trias
- Sangamo Therapeutics, 501 Canal Boulevard, Richmond, CA 94804, USA
| | - Jada Padilla
- Sangamo Therapeutics, 501 Canal Boulevard, Richmond, CA 94804, USA
| | - Hung Tran
- Sangamo Therapeutics, 501 Canal Boulevard, Richmond, CA 94804, USA
| | - Kathleen Meyer
- Sangamo Therapeutics, 501 Canal Boulevard, Richmond, CA 94804, USA
| | - Richard Surosky
- Sangamo Therapeutics, 501 Canal Boulevard, Richmond, CA 94804, USA
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