A practical workflow for CAR screening in primary T cells using fitness-guided design and mRNA electroporation

Chimeric antigen receptor (CAR) T cell therapy has achieved remarkable therapeutic outcomes in hematological cancers. However, broader clinical use has uncovered substantial challenges arising from intrinsic properties of both T cells and tumor tissues. As the functional phenotype of CAR T cells is affected by the CAR molecular architecture, optimizing CAR constructs continues to be a critical and ongoing task. Here, we present a practical workflow for scalable screening of CAR variants in primary T cells using fitness-guided design and mRNA electroporation. Using a CD19-targeted second-generation CAR, we built a library of point mutants that focused mutagenesis on hinge and costimulatory domains. Amino acid substitutions were prioritized using the sequence-based zero-shot fitness predictor to enrich evolutionarily tolerated variants. From 340 designed variants, we electroporated mRNA encoding 85 constructs into primary human CD8+ T cells and quantified cytotoxicity against CD19-positive Nalm6 cells. Twenty-four variants reproducibly exceeded wild-type cytotoxicity across three runs, and three hits were selected for lentiviral validation. One of the selected variants showed significantly improved cytotoxicity despite lower expression frequency and exhibited higher CD62L within CAR-positive cells, suggesting enhanced intrinsic function with a less differentiated phenotype. This approach enables scalable, rapid discovery of improved CAR domain variants directly in primary T cells.