Multifunctional Microfluidic Chip for Rapid Vector Genome and Empty Capsid Quantitation in AAV Vector Production

A dual functional microfluidic chip utilizing CRISPR-based DNA quantification and a washing-free sandwich assay for at-line capsid quantification in a miniaturized format, delivering fast, reliable, and accurate determination of the empty-to-full capsids.
Categories
Cell and Gene therapies
Process control
Project status
100% Completed

Industry Need

The gene therapy industry lacks an analytical method for AAV empty-to-full capsid characterization that combines speed, affordability, precision, and automation, comparable to the robust standards of protein therapeutics. Current methods, while effective, are either time-consuming, costly, or require specialized equipment and expertise, creating a critical need for a purpose-built technology to streamline manufacturing workflows.

Solution

A microfluidic chip-based CRISPR diagnostic platform offers a rapid, cost-effective, and precise solution for AAV empty-to-full capsid characterization by leveraging the programmable detection capabilities of Cas12a and fluorescence-based readouts. This technology enables multiplexed detection of AAV genome sequences, including synthetic ITR targets, with high sensitivity (~4.2 pM), minimal material requirements, and compatibility with simple, smartphone-based readers. Combined with washing-free D4 protein quantification assays, the platform could provide a comprehensive, automated analytical tool tailored for gene therapy manufacturing.

Outputs/Deliverables

  • CRISPR-AAV genome assay chip delivering an LOQ ≤ 1×1010 vg/mL, ≤ 45 min time to result, ≥ 2 weeks storage lifetime, and ≤ $1.00 per channel. [Complete]
  • Washing-free assay for capsid titration with LOQ ≤ 1×1011 cp/mL, ≤ 30 min time to result, ≥ 2 weeks storage lifetime, and < 40% CV. [Complete]
  • AAV chip incorporating D4 and CRISPR functionalities highly functional with all tested additives [Incomplete]

Impacts

This technology has the potential to streamline gene therapy process development, manufacturing validation, and continuous QC characterization.

Successful implementation of this project could pave the way for an additional powerful technique in the biomanufacturing PAT toolbox.

Publications

Hetzler, Z., Marinakos, S. M., Lott, N., Mohammad, N., Lass-Napiorkowska, A., Kolbe, J., Turrentine, L., Fields, D., Overton, L., Marie, H., Hucknall, A., Rammo, O., George, H., & Wei, Q. (2024). Adeno-associated virus genome quantification with amplification-free CRISPR-Cas12a. Gene Therapy, 31(5-6), 304-313. https://doi.org/10.1038/s41434-024-00449-x

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Project Lead

North Carolina State University

North Carolina State University

Participating Organizations

Biostealth Inc.

Biostealth Inc.

MilliporeSigma/EMD Serono

MilliporeSigma/EMD Serono