The
existing manufacturing protocols for CAR-T cell therapies pose
notable challenges, particularly in attaining a transient transfection
that endures for a significant duration. To address this gap, this
study aims to formulate a transfection protocol utilizing multiple
lipid-based nanoparticles (LNPs) administrations to enhance transfection
efficiency (TE) to clinically relevant levels. By systematically fine-tuning
and optimizing our transfection protocol through a series of iterative
refinements, we have accomplished a remarkable one-order-of-magnitude
augmentation in TE within the immortalized T-lymphocyte Jurkat cell
line. This enhancement has been consistently observed over 2 weeks,
and importantly, it has been achieved without any detrimental impact
on cell viability. In the subsequent phase of our study, we aimed
to optimize the gene delivery system by evaluating three lipid-based
formulations tailored for DNA encapsulation using our refined protocol.
These formulations encompassed two LNPs constructed from ionizable
lipids and featuring systematic variations in lipid composition (iLNPs)
and a cationic lipoplex (cLNP). Our findings showcased a notable standout
among the three formulations, with cLNP emerging as a frontrunner
for further refinement and integration into the production pipeline
of CAR-T therapies. Consequently, cLNP was scrutinized for its potential
to deliver CAR-encoding plasmid DNA to the HEK-293 cell line. Confocal
microscopy experiments demonstrated its efficiency, revealing substantial
internalization compared to iLNPs. By employing a recently developed
confocal image analysis method, we substantiated that cellular entry
of cLNP predominantly occurs through macropinocytosis. This mechanism
leads to heightened intracellular endosomal escape and mitigates lysosomal
accumulation. The successful expression of anti-CD19-CD28-CD3z, a
CAR engineered to target CD19, a protein often expressed on the surface
of B cells, was confirmed using a fluorescence-based assay. Overall,
our results indicated the effectiveness of cLNP in gene delivery and
suggested the potential of multiple administration transfection as
a practical approach for refining T-cell engineering protocols in
CAR therapies. Future investigations may focus on refining outcomes
by adjusting transfection parameters like nucleic acid concentration,
lipid-to-DNA ratio, and incubation time to achieve improved TE and
increased gene expression levels.