Background & Aim Pluripotent stem cell (PSC)-derived therapies have the potential to serve as “off-the-shelf” allogenic treatments for a wide range of chronic indications including cardiovascular and neurodegenerative diseases. These therapies target large patient populations and require high doses of ≥109 cells making them unsuited to traditional 2D culture-ware that are manual, open and poorly scalable technologies with limited in-process monitoring and increased risk and cost of batch failure. The commercial success of allogeneic PSC-derived therapies relies on the design and development of controlled, robust and cost-efficient processing platforms for large-scale manufacture. Methods, Results & Conclusion Here we present the development of a closed, scalable, automated and affordable upstream process for the expansion of PSCs in high-density, aggregate based culture in stirred tank reactors (STR). Production of PSCs at scale requires a seed train to generate the numbers needed to seed a bioreactor. This step is typically open, manual and labour intensive and at high risk for contamination and concomitant batch failure. We show this process step can be closed and automated effectively using a hollow fiber bioreactor system, able to produce up to 2 × 109 cells. Resulting cells were single seeded onto the STR and expanded using periodic settling to allow for automated medium exchange. An effective 3D-aggregate expansion was achieved with a 12-fold cell expansion over six days, with retention of pluripotency markers and differentiation potential. However, we found periodic settling reduces the ability to control aggregate size- a critical parameter that impacts expansion and differentiation. To overcome this, we investigated an acoustic perfusion system to enable STR process intensification with controlled and automated media exchange. We show cell retention ability (91.5±2.5%), increased control on aggregate size and maintenance of pluripotency markers. We also show the ability of the resulting aggregates to differentiate into the three germ layers. In parallel, different impeller speeds were screened at a 1500-mL scale to identify a suitable scaling factor between stirred tank reactors for the baseline process developed at 130-mL. Finally, integrated technologies were used for process concentration and wash. We, at Cell and Gene Therapy Catapult, have developed a closed, scalable and automated process for the expansion of PSCs up to 1500-mL scale.
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