SMART Sensors for Cell Growth Monitoring in Closed System G-Rex for Scalable, Cost-Conscious Cell and Gene Therapy Manufacturing

Abstract

Cell and gene-modified cell therapy (CGT), commonly referred to as the fourth pillar of cancer treatment, includes creating advanced cancer killing cells ex vivo and then subsequently putting them into the patients body to selectively attack cancerous cells. Typically, immune cells from a patients body are removed, genetically modified to find and kill cancer, grown to a large army of cancer killing cells, and put back into the patient. This complex process is being simplified through innovation, some of which we describe here. One key innovation is an immune cell manufacturing device configuration called G-Rex (for "gas permeable rapid expansion"), which is now widely used to create armies of cancer killing cells for clinical trials and for commercially approved drug products on a worldwide basis. G-Rex is uniquely simple and popular because it is the only technology that eliminates the need for pumps and flow circuits to deliver oxygen and nutrients. Instead, the material and geometry of G-Rex allow cancer killing cells to get access to oxygen and nutrients on demand. This greatly minimizes complexity and sets the stage for high throughput manufacturing. To further simplify G-Rex relative to all CGT drug product manufacturing alternatives, it would be ideal to eliminate any need of physical intervention to assess cell quantity. With that goal, we conceived a novel approach to determining cell quantity in a non-invasive manner. More specifically, we invented and built a sensor into G-Rex that continuously reports the quantity of cells in G-Rex without any intervention or sampling to an external reader. Herein, we call the sensor a "single-use metabolite absorbing resonant transducer in G-Rex (SMART G-Rex)" and the reader a "SMART Reader." The SMART G-Rex is wirelessly interrogated by the SMART Reader to determine the extent of cell expansion in the G-Rex at any given time. More specifically, as cell quantity increases, the SMART G-Rex absorbs cell secreted metabolites (organic compounds such as eicosanoids) which cause a change in resonant frequency (measured as % of frequency change, or Skroot Growth Index (SGI)). By placing SMART G-Rex in proximity of the SMART Reader, whether in or out of an incubator, changes in resonant frequency are detected and translated into cell quantity with high reliability. For example, using 45 sensors across multiple donor cell samples, we established 99% confidence in SMARTs accuracy at signaling a >60X expansion (3B cells at harvest). The SMART G-Rex provides a non-invasive way of instantly quantifying the number of cells in a CGT drug production process and informing manufacturers when a CGT drug product has reached the desired quantity of cells necessary to proceed with formulation, fill, and finish. By integrating SMART technology, G-Rex is the only technology for CGT manufacturing that can avoid intervention when determining cells quantity or allow real-time knowledge of cell quantity. Graphical Abstract O_FIG O_LINKSMALLFIG WIDTH=200 HEIGHT=83 SRC="FIGDIR/small/676768v1_ufig1.gif" ALT="Figure 1"> View larger version (34K): org.highwire.dtl.DTLVardef@1557118org.highwire.dtl.DTLVardef@740652org.highwire.dtl.DTLVardef@14b0430org.highwire.dtl.DTLVardef@ac0_HPS_FORMAT_FIGEXP M_FIG C_FIG