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Automation and AI Will Drive Next-Gen CAR T Manufacturing
The remarkable clinical success of CAR T therapies in blood cancers has validated the promise of engineered cell therapies. But according to Adam Janvier, PhD, head of cell therapy at eXmoor Pharma, the industry faces a crucial challenge: transforming highly personalized, labor-intensive manufacturing into scalable, commercially viable production systems.
“The next big thing that really needs to come through is how we can start tackling solid tumors,” Janvier says. “Until solid tumor is truly tackled, we’re always going to be missing that key next step of what CAR T has the promise to do.”
Although scientific hurdles remain, Janvier emphasizes that manufacturing constraints are equally pressing. Today’s autologous CAR T therapies rely on harvesting a patient’s own immune cells, engineering them outside the body, and reinfusing them after a manufacturing process that can stretch to two weeks. For critically ill patients, that timeline can prove devastating.
“We might fail a process because the donation just isn’t good enough,” he explains, referring to inconsistent starting material collected from heavily pretreated cancer patients. “Then we’ve got a four to six week vein-to-vein time due to manufacturing, testing, and logistics, where the patient might pass away during the period.”
The dual risks of manufacturing failure and lengthy turnaround times are pushing developers and contract development and manufacturing organizations (CDMOs) toward alternative strategies. Among the most promising are allogeneic, or off-the-shelf, CAR T therapies and emerging in vivo approaches that could eliminate ex vivo manufacturing altogether.
“There’s a lot of work going on now with in vivo CAR T,” Janvier says. “Instead of taking a blood donation as starting material, there is growing evidence that we could use the reprogramming technology directly with the patient, generating functional CAR T cells in situ.” Although such approaches remain early-stage, they represent a potential paradigm shift by reducing manufacturing time, simplifying logistics, and lowering costs.
Analytics and quality control also remain major bottlenecks. Current CAR T testing workflows rely heavily on expensive, time-consuming assays, including flow cytometry, qPCR, and tests to confirm the quality and safety of the lentivirus. Janvier believes that AI could eventually streamline many of these processes.
“One of the exciting technologies coming out is AI-based flow-cytometry approaches,” he says, pointing to emerging platforms that use label-free imaging and machine learning to characterize cells without fluorescent antibodies. “All of a sudden, you’re removing the need for antibodies and fluorophores, reducing the cost,” he says.
Still, Janvier argues that automation might ultimately become the defining factor in whether CAR T therapies can achieve widespread commercial adoption. Current cleanroom manufacturing remains highly manual, requiring specialized staff and flexible—but inefficient—facility layouts. “Once we approach commercial scale, batch costs need to have substantially decreased,” he says. “Automation can really support that.”
Janvier envisions future CDMOs operating sophisticated robotic manufacturing platforms capable of running around the clock while minimizing operator variability and contamination risk. However, implementing such systems will require substantial capital investment and new technical expertise. “These are not going to be inexpensive methods to implement into facilities,” he notes. “They’re going to be a large capital investment, and also a large people investment.”
Beyond manufacturing hardware, Janvier believes structural changes must begin much earlier in therapy development. Many CAR T programs originate in academic laboratories focused primarily on biological innovation rather than manufacturability or commercial scalability. “What can be missed there is the translation starting at the very beginning,” he says. “You need to start with the end in mind.”
That means considering GMP compatibility, scalability, cost-of-goods analysis, and automation readiness long before therapies enter clinical trials. Investors, Janvier adds, are increasingly demanding evidence that therapies can ultimately be manufactured at scale—not simply that the science is compelling.
The post Automation and AI Will Drive Next-Gen CAR T Manufacturing appeared first on GEN – Genetic Engineering and Biotechnology News.
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STAT+: At hospital finance conference, a call to end the friction that’s keeping costs high
NATIONAL HARBOR, Md. — At this week’s annual meeting of hospital finance leaders, the exhibit hall was packed with dozens of billing and collections companies. Armed with candy, tote bags, and pens, they smiled at passersby, eager to explain why their tactics would extract the most money from health insurers.
The sheer number of “revenue cycle” vendors who attended the Healthcare Financial Management Association’s annual conference in Maryland — outnumbering even the hospital attendees, according to a list shared by an organizer — was a visible reminder of the enormous industry built around just paying medical bills.
The U.S. health care industry spends roughly $200 billion annually on financial transactions: claims processing, payment, collections, and prior authorization. And yet the proliferation of billing vendors seemed to clash with the main theme of HFMA’s conference, affordability, spotlighting the need to simplify the billing process so that health care is less costly and more accessible for patients.
NATIONAL HARBOR, Md. — At this week’s annual meeting of hospital finance leaders, the exhibit hall was packed with dozens of billing and collections companies. Armed with candy, tote bags, and pens, they smiled at passersby, eager to explain why their tactics would extract the most money from health insurers.
The sheer number of “revenue cycle” vendors who attended the Healthcare Financial Management Association’s annual conference in Maryland — outnumbering even the hospital attendees, according to a list shared by an organizer — was a visible reminder of the enormous industry built around just paying medical bills.
The U.S. health care industry spends roughly $200 billion annually on financial transactions: claims processing, payment, collections, and prior authorization. And yet the proliferation of billing vendors seemed to clash with the main theme of HFMA’s conference, affordability, spotlighting the need to simplify the billing process so that health care is less costly and more accessible for patients.
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Beyond sunshine: Iberia’s biotech moment has arrived with developing capital networks
Strong science, lower costs and growing capital networks are putting Spain and Portugal on the biotech investment map, even as structural bottlenecks persist, according to two investors.
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Laser‑Driven Phase Contrast Enhances Cryo‑EM Resolution of Small Proteins
You know when you are at the eye doctor getting an updated prescription, and suddenly the world snaps into sharper focus? Physicists at the University of California (UC), Berkeley, have now done something similar for electron microscopy. By introducing phase contrast into a cryo‑electron microscope, they have delivered dramatically sharper images of some of biology’s smallest and most elusive proteins.
The advance comes from a new laser phase plate (LPP), described in the paper “Laser phase plate improves structure determination of small proteins by cryo‑EM,” which was published recently in Science. Led by physicist Holger Mueller, PhD, of UC Berkeley and Lawrence Berkeley National Laboratory, the team demonstrated that a laser‑driven phase plate can overcome one of cryo‑EM’s most persistent limitations: poor contrast for small proteins.

Cryo‑EM has transformed structural biology over the past decade, earning a Nobel Prize in 2017 for enabling high‑resolution structures without crystallization. But despite its impact, the technique still struggles with proteins below ~70 kilodaltons—a size range that includes about 90% of the human proteome. “Because of signal-to-noise limitations, the majority of human and animal proteins are too small to be analyzed by these methods [cryo-EM and cryoelectron tomography]. The increase in signal-to-noise ratio provided by this laser phase plate is expected to overcome these important limitations.”
The new LPP begins to address that problem. The LPP uses an intense, continuous‑wave laser to shift the phase of the electron beam itself. This produces true phase contrast without dimming or destabilizing the beam. Mueller described the laser focus as “75 kilowatts focused to a few microns… That’s more powerful than what you use for welding. It has more power than a military laser. It builds up the brightest continuous laser focus ever.”
Installed in a custom Thermo Fisher Titan Krios, the LPP immediately improved the clarity and resolvability of small proteins, including hemoglobin, which sits at the lower limit of what today’s cryo‑EM instruments can handle. As the authors wrote in the abstract: “Here, we show that the laser phase plate (LPP)… enhances the resolution in single-particle reconstruction of small proteins by improving specimen-motion correction, recovery of information from the early frames, as well as particle visualization, 3D classification, and alignment.”

These improvements were achieved using standard defocus ranges and reconstruction workflows. “For the most challenging cases—small particles, bad specimens—the laser produces a very considerable advantage,” Mueller said.
The impact extends beyond single‑particle analysis. Cryo‑electron tomography (cryo‑ET), which assembles multiple angular views of a molecule or protein into a three-dimensional image, stands to benefit even more. “With cryo-ET, we’re looking at small, very complicated cellular material that’s incredibly crowded inside the cell,” said Bridget Carragher, PhD, founding technical director of imaging at Biohub. “It’s like a forest of trees, and you’re trying to find one leaf on one tree in there. Cryo-ET needs a dramatic step forward in contrast, so we can start to see what’s going on inside the cell. That’s what the laser phase plate promises to give us.”
Biohub is developing a dual‑laser version of the system, designed to reduce component wear and minimize aberrations. Meanwhile, Mueller’s team is pushing toward imaging proteins as small as 17 kilodaltons, a threshold that would open access to vast regions of the human proteome previously invisible to cryo‑EM.
“This technology is a step function change for biology,” said Stephani Otte, PhD, Biohub’s vice president of imaging science. “What was once invisible will become visible—and that changes everything about how we understand disease.”
“The bottom line is, if you have a large protein and a really good sample—a fresh one or one frozen without bubbles, for example—you may not need the phase plate to get a single, high-quality image. But for a small protein and a bad sample, laser-on is best,” Mueller said. “This could fill an enormous gap in our knowledge of protein structures that can’t be crystallized or are too small for today’s cryo-EM. And it will be revolutionary for cryo-ET.”
The post Laser‑Driven Phase Contrast Enhances Cryo‑EM Resolution of Small Proteins appeared first on GEN – Genetic Engineering and Biotechnology News.
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