Viral Vector and Plasmid Manufacturing Market Size, Share and Trends Analysis, By Type (Viral Vectors, Plasmid DNA, and Non-viral), By Workflow (Upstream Manufacturing and Downstream Manufacturing), By Development Phase, By Indication, By Application, By End-Use, and By Region, Forecast 2025-2032

Viral Vector and Plasmid Manufacturing Market Overview and Key Insights:

Viral vector and plasmid manufacturing market size reached USD 5.25 billion in 2024 and is expected to register a revenue CAGR of 19.7% during the forecast period. The use of plasmid DNA in the creation of viral vectors for gene therapy is a significant achievement in medical science. Viral vectors, such as retroviral, adenoviral, and lentiviral vectors, are important in gene therapy because of their high transduction efficiency and sustained gene expression. Plasmid DNA and lentiviral vector (LVV) are commonly utilized as delivery vehicles in CGT products; nevertheless, process development and production of plasmid and LVV face numerous problems, including high cost, a lack of clinical grade supply, scaling up, low yield, and so on.

Market Drivers:

Growing prevalence of chronic diseases is a key driver of revenue growth in viral vector and plasmid manufacturing market. The National Cancer Institute predicts that around 72,680 people in the United States will be diagnosed with cancer of the oral cavity, pharynx, or larynx, the three most common kinds of head and neck cancer, by 2025. Alcohol and tobacco use are the two most significant risk factors for head and neck cancer. Approximately 69 percent of persons with oral cavity or pharyngeal cancer will live for five years or more after being diagnosed.

Reliable production systems are critical to the effective introduction of viral vector medicines into clinics. Indeed, the development of robust manufacturing skills has enabled the widespread use of recombinant biotherapeutics such as monoclonal antibodies. Currently, the four most explored viral vectors in clinical trials are adenovirus (Ad), adeno-associated virus (AAV), herpes simplex virus (HSV), and retrovirus (RV). Furthermore, new viral vectors for tumor therapy are being developed, including vaccinia virus (VV), reovirus (Reo), alphavirus, Zika virus (ZIKV), and vesicular stomatitis virus (VSV).

On June 2025, ProBio, a global contract development and manufacturing organization (CDMO) focusing in cell and gene therapy, has announced the launch of its flagship Cell and Gene Therapy Center of Excellence on the Princeton West Innovation Campus in Hopewell, NJ. ProBio’s 128,000-square-foot GMP laboratory produces high-quality plasmid DNA and viral vectors, including AAV and LVV platforms, demonstrating their commitment to speeding the delivery of breakthrough medicines.

Market Opportunity:

Integration of AI in viral vector technology acts as opportunities for viral vector and plasmid manufacturing market. The rise of artificial intelligence (AI), particularly machine learning, has the potential to speed capsid optimization while shortening development time and costs. This method can process massive amounts of biological data, swiftly identifying viable capsid designs that improve anticipated AAV packing and cell transduction efficiency. As a result, ML not only speeds up the experimental procedure, but it also makes it easier to build innovative AAV capsids that would be difficult to develop using traditional methods, thereby boosting therapeutic efficacy and safety.

On July 2025, Myrtelle Inc., a pioneering clinical-stage gene therapy company dedicated to revolutionizing neurodegenerative disease treatment, has announced the official start of commercial-stage manufacturing for its first-in-class oligotrophic recombinant adeno-associated virus (rAAV) gene therapy product, which was developed specifically for Canavan disease. The manufacturing effort is carried out in strategic partnership with two global leaders in gene therapy infrastructure: Charles River and Viralgen Vector Core.

Recent Trends:

Emerging trends include upstream production & platform innovation, downstream processing & purification advances, vector/plasmid design & engineering, and digitalization & smart manufacturing.

Viral vector processing is vital for producing gene treatments, vaccines, and biopharmaceuticals. Viral vectors, including lentiviruses, adenoviruses, and adeno-associated viruses (AAVs), are commonly used to deliver therapeutic genes to target cells. Downstream processing techniques are determined by the unique characteristics of each viral vector. Adenoviral vectors’ robustness and resistance to environmental conditions may necessitate gentler purification techniques. Integrating lentiviral vectors into the host genome requires meticulous DNA clearing during downstream processing to assure safety. AAV vectors, with their small size and distinctive capsid structure, may require specialized chromatographic procedures for purification.

On May 2025, 3PBIOVIAN, a renowned CDMO partner in biopharmaceutical manufacturing, has proudly announced the debut of the AAVion Platform, a fully integrated adeno-associated virus (AAV) manufacturing system designed to expedite gene therapy development. AAVion Platform provides biotech and pharmaceutical firms with a seamless end-to-end journey from in-house plasmid manufacture to aseptic fill and finish, reducing timeframes and costs while simplifying the path to the clinic.

Restraints & Challenges:

Scalability poses a significant challenge in viral vector generation.  The ability to smoothly scale up and scale up viral vector production is crucial for addressing the growing demand for gene therapy and cell therapy products, as well as conducting rigorous clinical trials. Traditional techniques of producing viral vectors may have inherent scaling limits. Taking the production processes from laboratory to large-scale commercial production presents significant hurdles. These issues may include preserving product quality, optimize procedures, and assure cost effectiveness. The limitations of traditional methodologies can restrict the rapid progression of preclinical investigations, delaying advances in gene therapy.

Type Segment Insights and Analysis:

Based on the type segment, viral vector and plasmid manufacturing market is segmented into viral vectors, plasmid DNA, and non-viral.

Viral vectors segment contributed the largest market share in 2024. It is further sub segmented into adenovirus, retro-virus, Adeno-Associated Viruses (AAV), lentiviruses, and others. Manufacturing technology for producing clinical-grade viral vectors have advanced dramatically in recent years. Viral vectors have become a popular technique for delivering genetic payloads to numerous target tissues, consolidating their role in gene therapy, as indicated by the recent increase in regulatory approvals and the quickly expanding landscape of clinical trials.

A major production decision is whether to establish manufacturing capacity in-house or outsource to specialist CDMOs. Using external manufacturing platforms can speed up production while also providing access to technical and regulatory expertise, as well as reliable GMP-certified facilities and materials. The usage of bioreactors provides advantages in terms of expanding production scale because it simplifies the process by using fewer bigger vessels. Other benefits include improved process monitoring and control, less record keeping, fewer unit operations, lower contamination hazards, less facility space, and cheaper operating expenses.

On May 2025, Univercells Technologies, has launched the scale-X nitro controller, the latest addition to its scale-X fixed-bed bioreactor range. The new controller, part of the scale-X platform, is designed to operate both the 200 and 600 m² scale-X nitro bioreactors. It provides a cost-effective, low-footprint, and user-friendly solution for large-scale viral and advanced therapy manufacturing, delivering high productivity and rapid scalability from R&D to commercial production in just eight months. It supports both adherent and suspension cell cultures, making it ideal for a variety of applications such as viral vaccines, exosomes, LV and AAV vector generation, oncolytic viruses, and recombinant proteins.

Indication Segment Insights and Analysis:

Based on the indication, viral vector and plasmid manufacturing market is segmented into cancer, generic disorders, cardiovascular & metabolic diseases, neurological/CNS diseases, infectious disease, others.

Cancer segment contributed the largest market share in 2024. Plasmid DNA and viral vector technologies are becoming increasingly important in the development of precision oncology treatments, with an emphasis on tailoring therapy to individual cancer types and patient profiles, providing patients more hope for cancer elimination and a long-term cancer-free life. Many of the oncolytic viruses now being studied in clinical trials are weakened variants of common human infections. They have been genetically modified to lower pathogenicity while increasing oncolytic potency and cancer tissue selectivity. Clinical trials include RNA and DNA viral vector-based vaccinations and cancer therapies.

In recent years, nanoparticles have been widely used to deliver powerful biomolecules to malignant cells as a therapeutic. Nanoparticles range in size from 1 to 100 nm, making them easily manipulated to resist host endogenous and catabolic enzymes and transport therapeutic genes into cancer cells by gene silencing, anti-sense treatment, RNA interference, and gene and genome editing.

On June 2024, Charles River Laboratories International, Inc. and Captain T Cell have signed a plasmid DNA and retrovirus vector production program agreement. Captain T Cell will gain access to established plasmid and viral vector contract development and manufacturing organization (CDMO) capabilities as part of Charles River’s Cell and Gene Therapy (CGT) Accelerator Program (CAP), as well as advisory services, in advance of the company’s plan to manufacture a TCR-T cell therapy for solid tumor patients for a Phase I clinical trial.

Application Segment Insights and Analysis:

Based on the application, viral vector and plasmid manufacturing market is segmented into cell and gene therapy, vaccine development, and genetic engineering & research.

Cell and gene therapy segment contributed the largest market share in 2024. Gene treatments are transformative for the future of medicine and patient success, especially for diseases with few or no existing therapeutic options. Cell and gene therapies are extremely advanced medical treatments that treat or potentially cure diseases by addressing underlying genetic reasons or improving cellular functions through the introduction or induction of optimum cellular activity. Because the impacts of gene editing on patients are unlimited, this medical discovery has numerous applications and patient outcomes.

On January 2023, Catalent, a global leader in facilitating the discovery and supply of better treatments for patients, has announced the establishment of a new commercial-scale plasmid DNA (pDNA) manufacturing facility at its European centre of excellence for cell therapies in Gosselies, Belgium. This commercial-scale pDNA facility is the most recent addition to Catalent’s Gosselies campus, which offers comprehensive services for all stages of cell and gene therapy development, including process and analytical development laboratories, technical transfer services, CGMP cleanrooms for manufacturing, dedicated quality control laboratories, a Qualified Person (QP), and warehousing and logistics support.

Geographical Outlook:

Viral vector and plasmid manufacturing market is strategically segmented by geography to provide a comprehensive understanding of regional market dynamic. Discover demand analysis, emerging trends, and growth opportunities shaping market performance across different region and countries.

North America Viral Vector and Plasmid Manufacturing Market:

North America is registered to have highest market share in viral vector and plasmid manufacturing market in 2024 driven by the presence of major producers operating large, well-established facilities with extensive supply chain networks throughout the United States, Canada, and Mexico. These manufacturers gain advantages from economies of scale, advanced automation systems, and adherence to stringent regional quality and safety regulations, enabling them to serve a wide range of end-use industries. Additionally, the market is being influenced by ongoing technological advancements, sustainability-focused practices, and growing demand for high-quality, cost-effective products.

On May 2023, AGC Biologics, a global leader in biopharmaceutical contract development and manufacturing (CDMO), has announced the launch of its BravoAAV and ProntoLVV viral vector platforms. AGC Biologics’ innovative platforms provide quick, efficient, and reproducible clinical and commercial GMP production and release, drawing on three decades of LVV and AAV development, manufacturing, and analytical experience. The BravoAAV and ProntoLVV platforms are produced at various sizes, with suspension up to 2,000 L and adhesion up to 750 L, and contain prequalified scale-down versions that simplify and accelerate the approach to commercialization.

Asia Pacific Viral Vector and Plasmid Manufacturing Market:

Asia Pacific is expected to register the fastest growth rate during the forecasted period, driven by rapid expansion of the gene & cell therapy pipeline, rising demand from mRNA and DNA vaccine manufacturing, and advancements in manufacturing technologies. With growing emphasis on personalized medicine across the region, the demand for viral vectors particularly adeno-associated viruses (AAV) and lentiviral vectors has significantly increased, as these vectors are essential for delivering genetic material in therapeutic applications. In addition, countries like China and India are quickly enhancing their biomanufacturing capabilities. This progress is being supported by government initiatives, collaborations with academic institutions, and strategic partnerships between international biotech companies and regional manufacturers.

On September 2025, Matica Biotechnology, Inc., a leading contract development and manufacturing organization (CDMO) specializing in viral vector production, and Cirsium Biosciences have formed a non-exclusive strategic relationship. This cooperation exemplifies Cirsium’s hybrid hub-and-spoke manufacturing architecture, which combines internal plant-based AAV production capabilities with downstream partners to maximize flexibility, scalability, and distribution.

Europe Viral Vector and Plasmid Manufacturing Market:

Europe is expected to have considerable market share in 2024, driven by rapid expansion of the gene & cell therapy pipeline and rising demand from mRNA and DNA vaccine manufacturing. On February 2025, Novartis in Slovenia has opened the new viral vector production plant (VIFA One) in Mengeš. Novartis’ EUR 40 million investment considerably enhances its biopharmaceutical research and production capabilities, while also strengthening Slovenia’s essential role within one of the world’s leading pharmaceutical corporations. The specialist VIFA One facility will aid in the development of viral vectors for breakthrough cell and gene treatments to treat autoimmune and hereditary illnesses, as well as cancer.

Competition Analysis:

Viral vector and plasmid manufacturing market is characterized by a fragmented structure, with several players competing across various segments and regions. List of major players included in viral vector and plasmid manufacturing market report are:

• Thermo Fisher Scientific
• Charles River Laboratories
• Catalent, Inc
• Merck
• FUJIFILM Biotechnologies
• Oxford Biomedica PLC
• Cojourney, Inc.
• Lonza Group Ltd.
• Advanced Therapies, LLC
• Bionova Scientific LLC
• Aldevron LLC
• Batavia Biosciences B.V.
• Genezen Laboratories, Inc.
• Takara Bio. Inc.
• Esco Aster Pte. Ltd.

Strategic Developments in Viral Vector and Plasmid Manufacturing Market:

• In August 2025, WACKER and Gearbox Biosciences have announced a strategic agreement to enhance plasmid DNA production technologies. The collaboration with Gearbox will focus on novel workflows for antibiotic-free plasmid DNA production and difficult-to-produce pDNA products. By harnessing the complementary skills of both parties, the collaboration aims to create solutions that are more sustainable than current technologies while simultaneously providing greater quality and shorter deadlines.
• In June 2025, ArcticZymes Technologies ASA has expanded its GMP product line with the release of M-SAN HQ GMP, a new GMP grade nuclease intended exclusively for viral vector synthesis. This new product combines M-SAN HQ’s proven effectiveness with the regulatory strength of GMP manufacturing, resulting in a highly effective solution for enzymatic host cell DNA removal under physiological salt circumstances. This makes it ideal to produce delicate viral vectors like lentiviruses and retroviruses, which are essential components of many modern medicines and vaccines.
• In May 2024, Charles River Laboratories International, Inc. has introduced its Modular and Fast Track viral vector technology (tech) transfer frameworks. Based on decades of viral vector contract development and manufacturing organization (CDMO) experience, the Company has developed a rigorous methodology to deliver effective, rapid process transfer to its Maryland-based viral vector center of excellence (CoE) in as few as nine months. Charles River’s viral vector technology transfer program provides phase-appropriate and configurable frameworks to provide excellent stability, reducing costly and time-consuming program delays.

Key Advantages for Stakeholders:

Navistrat Analytics’ industry report provides an in-depth quantitative analysis of various market segments, historical and current trends, market forecasts, and dynamics within the global market. The historical years covered in this report are 2022 to 2023, with 2024 serving as the base year for market size calculations. The forecast period extends from 2025 to 2032.

The report includes an executive summary and a comprehensive overview of market drivers, restraints, opportunities, and challenges (DROC), along with insights into regulatory standards. It features detailed analyses such as PORTER’s Five Forces, SWOT, and PESTLE, as well as assessments of technological trends and the competitive landscape.

PORTER’s Five Forces analysis helps stakeholders evaluate the impact of new entrants, competitive rivalry, supplier power, buyer power, and substitution threats, enabling them to assess the level of competition and the attractiveness of the global market. The competitive landscape provides stakeholders with a clear understanding of the current market positions of key players, offering valuable insights into their competitive environment.

Scope And Key Highlights Of Viral Vector and Plasmid Manufacturing Market Report:

Viral Vector and Plasmid Manufacturing market report offers a detailed analysis of market size, including historical revenue (in USD Billion) data for 2022-2023 and revenue forecasts for 2025-2032 across the following segments:

• Type Outlook (Revenue, USD Billion; 2022-2032)
  • Viral Vectors
    • Adenovirus 
    • Retro-Virus
    • Adeno-Associated Viruses (AAV)
    • Lentiviruses
    • Others
  • Plasmid DNA
    • mRNA
    • Others
  • Non-Viral
    • Lipid/Polymer
    • Electroporation
    • Nanoparticles
    • Others

• Workflow Outlook (Revenue, USD Billion; 2022-2032)
  • Upstream Manufacturing
    • Vector Amplification & Expansion
    • Vector Recovery/Harvesting
  • Downstream Manufacturing
    • Purification
    • Fill Finish

• Development Phase Outlook (Revenue, USD Billion; 2022-2032)
  • Pre-Clinical Therapeutics
  • Clinical Therapeutics
  • Marketed Therapeutics

• Indication Outlook (Revenue, USD Billion; 2022-2032)
  • Cancer
  • Generic Disorders
  • Cardiovascular & Metabolic Diseases
  • Neurological / CNS Diseases
  • Infectious Disease
  • Others

• Application Outlook (Revenue, USD Billion; 2022-2032)
  • Cell and Gene Therapy
  • Vaccine Development
  • Genetic Engineering & Research

• End-Use Outlook (Revenue, USD Billion; 2022-2032)
  • Pharmaceutical & Biopharma Companies 
  • Academic and Research Institutes
  • Biopharmaceutical Companies
  • Contract Research Organizations (CRO) and CDMOs

• Regional Outlook (Revenue, USD Billion; 2022-2032)
  • North America
    • U.S.
    • Canada
    • Mexico
  • Europe
    • Germany
    • France
    • U.K.
    • Italy
    • Spain
    • Benelux
    • Nordic Countries
    • Rest of Europe
  • Asia Pacific
    • China
    • India
    • Japan
    • South Korea
    • Oceania
    • ASEAN Countries
    • Rest of APAC
  • Latin America
    • Brazil
    • Rest of LATAM
  • Middle East & Africa
    • GCC Countries
    • South Africa
    • Israel
    • Turkey
    • Rest of MEA

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