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Comparison of AAV1-9 production in adherent and suspension HEK293 cells suggests capsid engineering for improved AAV titres
KTH, School of Engineering Sciences in Chemistry, Biotechnology and Health (CBH), Protein Science, Protein Technology.ORCID iD: 0000-0002-7984-0744
KTH, School of Engineering Sciences in Chemistry, Biotechnology and Health (CBH), Protein Science, Protein Technology.ORCID iD: 0000-0001-7679-2145
KTH, School of Engineering Sciences in Chemistry, Biotechnology and Health (CBH), Protein Science, Protein Technology.ORCID iD: 0009-0004-2369-8920
KTH, School of Engineering Sciences in Chemistry, Biotechnology and Health (CBH), Protein Science, Protein Technology.ORCID iD: 0000-0003-1096-9061
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(English)Manuscript (preprint) (Other academic)
Abstract [en]

Adeno-associated viruses (AAVs) are the backbone of in vivo gene therapy, but patient access is hindered by high production costs. Adherent HEK293T cells are commonly used for AAV production in both development scale and large-scale, despite suspension HEK293F cells being the preferred format for industrial upscaling. As comparative studies of AAV production in adherent versus suspension HEK293 are scarce, we systematically evaluated the production of 10 different AAV serotypes in adherent HEK293T cells and suspension HEK293F cells. All serotypes produced at higher levels in adherent than suspension (4- to 19-fold increase in viral genome titres; 3- to 633-fold in capsid titres). Notably, AAV2 exhibited a 316-fold difference in secretion between adherent and suspension cells. Investigating the capsid protein sequences of 9 naturally occurring AAV serotypes, we identify 12 divergent regions, named Serotype Divergent Regions (SDRs), which could contribute to the observed differences in secretion. We created AAV hybrids by exchanging SDR-regions of a low-secreting (AAV2) and a highly secreting (AAV8) serotype, which demonstrated increased capsid secretion. Comparison of cell surface heparan sulphate proteoglycan expression levels, the class of receptor targeted by AAV2, revealed considerably lower expression levels on adherent HEK293T than suspension HEK293F.We postulate that capsid-glycan interactions can be engineered to increase AAV2 secretion and production.

National Category
Medical Biotechnology
Identifiers
URN: urn:nbn:se:kth:diva-387226OAI: oai:DiVA.org:kth-387226DiVA, id: diva2:2094349
Note

QC 20260824

Available from: 2026-08-21 Created: 2026-08-21 Last updated: 2026-08-24Bibliographically approved
In thesis
1. Engineering of viral surfaces and production methods for gene therapy applications
Open this publication in new window or tab >>Engineering of viral surfaces and production methods for gene therapy applications
2026 (English)Doctoral thesis, comprehensive summary (Other academic)
Abstract [en]

Several genetic diseases can now be treated using gene therapy. Adeno-associated viruses (AAVs) are widely used in these types of therapies as gene delivery vehicles, where the AAV genome is replaced with a therapeutic gene. However, AAV gene therapies are expensive due to challenging recombinant production. Additionally, AAVs are not organ-specific, increasing the dose required to reach efficacy. This drives up drug prices and risks of side effects, especially towards the liver. This thesis presents methods to improve AAV production and to make AAVs organ-specific.

AAV production requires plenty of plasmid DNA and in drug development phases of AAV-therapies, plasmid purification is highly manual. In the first article, automated plasmid purification is compared to a manual, industry-standard kit. The automated system lowered manual labour by up to 95 %, with similar or up to 14-fold higher AAV titres depending on the AAV production system. Transfection parameters were studied, showing larger transfection complex formation when using automatically purified plasmids.

The next two articles describe the main work of the thesis: the development of a modular platform for organ-selective AAVs. By attaching a type of affinity scaffold protein called Affibody molecules to the viruses, the AAVs became infectious only towards cells displaying the target receptor of the Affibody. The Affibody-AAVs demonstrated selective cell uptake in vitro and modified organ uptake in vivo, avoiding the liver. Cryo-electron microscopy (Cryo-EM) studies of Affibody-AAVs yielded a high-resolution protein structure at 1.67 Å, along with the first structural data of an affinity scaffold integrated into an AAV.

In the final paper, AAV-production was systematically compared between two common AAV production cell lines: adherent HEK293T and suspension HEK293F. HEK293T produced higher AAV titres than HEK293F (3 to 633- fold higher) and viruses secreted from HEK293T up to 316 times more. By creating AAV-hybrids, secretion was increased from HEK293F. Cell expression level studies of heparan sulphate proteoglycans (HSPGs), targeted by the AAV-variant AAV2, showed lowering of HSPG levels may improve AAV2 secretion.

In summary, this thesis describes methods for creating more efficient AAV gene therapies and for improving AAV production. The presented Affibody-AAV platform can also broaden the use of AAV gene therapies, by enabling targeting of AAVs to organs which naturally-occurring AAVs do not reach.

Abstract [sv]

Flera genetiska sjukdomar kan nu lindras med genterapier. Adeno-associerade virus (AAV) används i hög grad i dessa terapier, där AAV-genomet bytts ut mot en terapeutisk gen. AAV-terapier är dock väldigt dyra eftersom AAVer är svåra att producera rekombinant. Därtill är AAVer inte organspecifika, vilket ökar dosen som krävs för att få effekt. Priset drivs då upp samt risken för biverkningar, där levern är särskilt utsatt. Denna avhandling redogör för metoder för att förbättra AAV-produktionen och för att skapa organspecifika AAVer.

AAV-produktion kräver mycket plasmid-DNA och i utvecklingsfasen av AAV-terapier sker plasmidrening oftast manuellt. I avhandlingens första artikel jämförs automatisk plasmidrening med ett manuellt reningskit (industristandarden). Det automatiserade systemet minskade aktivt arbete med upp till 95 %, därtill med likvärdiga eller upp till 14 gånger högre AAV-titrar beroende på AAV-produktionssystem. Olika transfektionsparametrar studerades sedan, där vi såg att automatiskt renade plasmider ger större transfektionskomplex.

De nästkommande två artiklarna beskriver avhandlingens huvudarbete: utvecklingen av en modulär plattform för organspecifika AAVer. Genom att fästa affinitetsproteiner kallade Affibody-molekyler på virusen blev AAVerna infektiösa endast mot celler vars yta uppvisar den receptor som Affibody-molekylen har affinitet mot. Affibody-AAVerna uppvisade selektivt cellupptag in vitro samt förändrat organupptag in vivo, med kraftigt minskat upptag i levern. Kryo-elektronmikroskopi (Kryo-EM) av Affibody-AAV-viruset gav en högupplöst proteinstruktur vid 1.67 Å. Därtill presenteras strukturdata som visar hur Affibody-molekylen sitter på ytan av ett AAV.

Den sista artikeln jämför AAV-produktion mellan två vanliga AAV-produktionscellinjer: ytvidhäftande HEK293T och suspensionsväxande HEK293F. HEK293T tillverkade AAVer i högre titrar (3 till 633 gånger högre) än HEK293F, och virus utsöndrades upp till 316 gånger mer från HEK293T. Genom att skapa AAV-hybrider ökades utsöndringen. Studier i celluttryck av heparansulfatproteoglykaner (HSPG), som AAV-varianten AAV2 binder, visa att lägre HSPG-nivåer på HEK293F kan potentiellt öka AAV2-utsöndringen.

Sammanfattningsvis bidrar forskningen i denna avhandling till att skapa mer effektiva AAV-terapier samt till idéer för att förbättra AAV-produktionen. Därtill kan den presenterade Affibody-AAV-plattformen användas för att skapa nya genterapier för organ som naturligt förekommande AAVer inte infekterar.

Place, publisher, year, edition, pages
Stockholm, Sweden: KTH Royal Institute of Technology, 2026. p. 68
Series
TRITA-CBH-FOU ; 2026:35
Keywords
AAV, Adeno-associated virus, Affibody, affinity, biotechnology, cryogenic electron microscopy, Cryo-EM, HEK293, gene therapy, production, rational design, selective, AAV, Adeno-associerade virus, Affibody, affinitet, bioteknik, genterapi, HEK293, kryoelektronmikroskopi, Kryo-EM, produktion, rationell design, selektiv
National Category
Medical Biotechnology
Research subject
Biotechnology
Identifiers
urn:nbn:se:kth:diva-386732 (URN)978-91-8106-680-7 (ISBN)
Public defence
2026-09-25, Kollegiesalen, Brinellvägen 8, Stockholm, 09:30 (English)
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Supervisors
Note

QC 2026-08-21

Available from: 2026-08-21 Created: 2026-08-21 Last updated: 2026-09-07Bibliographically approved

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Thorell, HannesKarlander, MaximilianWistbacka, NumVolk, Anna-LuisaFresk, MatildaPintar, AntonVillacañas González, María del CarmenJung, TaeyangMalm, MagdalenaRockberg, Johan

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Thorell, HannesKarlander, MaximilianWistbacka, NumVolk, Anna-LuisaFresk, MatildaPintar, AntonVillacañas González, María del CarmenJung, TaeyangMalm, MagdalenaRockberg, Johan
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