An image depicting the letters ATCG, the building blocks of DNA, featured throughout the Hearth at Forge Biologics.

Expert AAV Development
& cGMP Manufacturing

At Forge, better manufacturing isn’t a benchmark—it’s a mindset. Through innovative technologies and continuous improvement, we deliver end-to-end AAV manufacturing services. Any stage. Any serotype. Built around your journey.

Forge team members at the Hearth pose for a group photo during Rare Disease Day.

Your AAV Partner from Idea to Impact

Gene therapy manufacturing takes more than infrastructure. It takes the right team, the right platform, and a partner at every step. Forge offers research-grade production, process development, and cGMP manufacturing alongside in-house plasmid production, molecular development, analytics, quality, fill-finish, stability, and regulatory support—all fully integrated to streamline your path forward.

AAV Manufacturing
that Meets You Where You Are

Whether you’re optimizing your AAV process or ready to scale, Forge offers manufacturing paths designed to meet you where you are.

advanced AAV platform

Accelerate with Our FUEL™ Platform

Still developing your process and need a manufacturing solution to streamline your path? Forge’s FUEL™ platform offers a powerful head start—an innovative AAV manufacturing foundation built to help you scale efficiently. With advanced technologies, proven processes, and flexible, product-specific optimizations, FUEL™ can increase productivity and recovery while maintaining product quality.

discovery support

Blaze Research-Grade AAV Production

Early-stage developers need fast, scalable access to research-grade material. Enter Blaze, our research-grade AAV production at 1–40L. Blaze is ideal for discovery work like material generation for proof-of-concept studies or assessing vector manufacturability. With a scalable process and Forge’s proprietary technologies, it gives early-stage developers confidence in a seamless path to cGMP.

Process, Perfected

Process Development

No two gene therapy programs are alike. That’s why our process development services are built around product-specific optimizations to drive success and cGMP readiness. With deep experience across natural and novel AAV serotypes and a broad range of indications, we’ve mapped 50+ upstream and downstream studies to help optimize yield, purity, and efficiency. Every strategy is tailored with time, cost, and long-term impact in mind.

A scientist at Forge Biologics programming lab equipment.

Consistency

cGMP Production

Maintaining consistency at cGMP scale is vital to program success, and you need a manufacturing partner who can reliably scale with you. Forge’s cGMP production—ranging from 50 to 5,000L—is designed for scalability, efficiency, and repeatable manufacturing success. Backed by deep technical expertise, our team leverages single-use technologies and optimized closed-system processes to produce larger batches with high throughput and minimal variability.

Scientists at Forge Biologics running chromatography in one of our downstream GMP suites.

Seamless Technology Transfer

Have a locked process and need a partner for manufacturing execution? Forge offers collaborative, systematic tech transfer services backed by deep AAV expertise. With in-house process knowledge and access to a wide range of development and production scales, we’re built to support your success from transfer through execution.

In-house advantage

Analytical Development & Quality Control

At Forge, precise analytics and quality aren’t add-ons—they’re the foundation of everything we do. We offer 25+ in-house AAV assays to accelerate characterization and release. Our integrated QC and QA framework, supported by cGMP compliance and connected systems, ensures consistent, compliant quality manufacturing from start to finish.

A technician at Forge Biologics in a lab.

Precision

Fill-Finish

Forge offers a range of fill-finish services to meet the needs of your program. We provide drug product fill options across automated, semi-automated, and manual operations, designed to accommodate varying batch sizes, container types, and fill volumes to suit your product requirements.

The fill-finish process with Forge's Watson Marlow Flexicon semi-automated filler.

stability starts here

Stability

For gene therapy developers, providing product stability is a critical step toward clinical and commercial success. That’s why Forge offers long-term frozen and accelerated stability testing as well as device compatibility studies, generating product-specific data from early-phase lots to evaluate the stability of the drug product across its intended use and storage conditions.

A row of test tubes with drug substance.

regulatory & molecular development

Supporting Services

Forge was built to be more than a manufacturer. We are a true partner, offering services and expertise to support your program from early development through cGMP and beyond. Our molecular development team provides early-phase guidance such as GOI construct evaluation for manufacturability. Our regulatory team works closely with clients to shape program strategy, offering support for agency interactions, CMC/IMPD documentation, and more. With AAV and plasmid Drug Master Files maintained in the U.S. and Canada, we deliver comprehensive support throughout the regulatory process.

The hearth

Our Industry-Leading Production Facility

To bring gene therapies to patients, you need a facility built for scale, flexibility, global readiness—and unwavering compliance. The Hearth, Forge’s 200,000+ sq. ft. GMP facility, is one of the largest manufacturing sites dedicated to AAV. With 20 cGMP suites and bioreactors ranging from 50 to 5,000L, it’s intentionally designed to increase throughput and support efficient production.

Hot off the Forge