Engineer CAR Cells Without Viral Vectors

CAR Cell Therapy

CAR Cell Engineering Capabilities

Non-Viral CAR Delivery

Deliver circRNA or mRNA encoding CARs directly to the cytosol without viral vectors, eliminating insertional mutagenesis risk and reducing manufacturing complexity.

Multi-Cell Compatibility

Engineer T cells, NK cells, and macrophages with the same platform. Consistent delivery across all major CAR cell types with consistent results across cell types.

Clinical-Scale Manufacturing

The MilliBooster cartridge integrates with GMP systems (Fresenius Kabi Lovo, Rotea) to process over 1 billion cells per run with high mRNA expression at scale.

Multiplexed Engineering

Simultaneously deliver multiple cargos in a single pass. Portal has achieved high triple-positive delivery of CRISPR RNP, mRNA, and dextran to T cells in one step.

Non-Viral CAR Delivery

Deliver circRNA or mRNA encoding CARs directly to the cytosol without viral vectors, eliminating insertional mutagenesis risk and reducing manufacturing complexity.

Multi-Cell Compatibility

Engineer T cells, NK cells, and macrophages with the same platform. Consistent delivery across all major CAR cell types with consistent results across cell types.

Clinical-Scale Manufacturing

The MilliBooster cartridge integrates with GMP systems (Fresenius Kabi Lovo, Rotea) to process over 1 billion cells per run with high mRNA expression at scale.

Multiplexed Engineering

Simultaneously deliver multiple cargos in a single pass. Portal has achieved high triple-positive delivery of CRISPR RNP, mRNA, and dextran to T cells in one step.

Explore detailed protocols and data in our CAR cell engineering app notes.

CAR Cell Engineering Workflows

Portal supports multiple CAR cell manufacturing approaches, from standard activated T cell workflows to rapid whole blood processing.

Workflow

Cell Type

Cargo

Key Result

circRNA CAR-T

Activated T cells

circRNA (CD19 CAR + mbIL-12)

75.9% dual-positive expression; >90% tumor cytotoxicity at 3:1 E:T

Whole Blood CAR-T

T cells (unprocessed whole blood)

mRNA (CD19 CAR + mbIL-2)

52.9% CAR+ IL-2+ T cells in <10 minutes; no preprocessing required

CAR-NK

NK cells

mRNA or circRNA (CAR construct)

Consistent delivery with maintained NK cell viability and cytotoxic function

Multiplexed CAR-T

Unstimulated T cells

CRISPR RNP + mRNA + dextran

85.7% triple-positive delivery; 59% B2M knockout at clinical scale

Validated CAR Cell Data

Dual circRNA Delivery for Functional CAR-T Cells

In collaboration with Massachusetts General Hospital, Portal has demonstrated simultaneous delivery of two circular RNAs encoding CD19 CAR and mbIL-12 to activated T cells. The resulting CAR-T cells achieved 75.9% dual-positive expression and >90% tumor cell killing at a 3:1 effector-to-target ratio, with viability maintained at >75%. circRNA offers extended protein expression compared to standard mRNA, providing a longer functional window without genomic integration.

CAR-T Cells Directly from Whole Blood

Portal has demonstrated generation of multi-engineered CAR-T cells directly from unprocessed whole blood, achieving high CAR+ IL-2+ T cell expression in under 10 minutes without cell separation or activation. Economic modeling suggests this workflow could dramatically reduce per-dose costs, with roughly 90% cost savings that could widely improve access to CAR-T therapy for B-cell lymphoma patients.

Clinical-Scale Validation with GMP Integration

Portal's MilliBooster cartridge has been validated at clinical scale with Fresenius Kabi's Lovo cell processing system, achieving 92–94% mRNA expression (consistent across research and clinical scale) and ~60% B2M knockout in T cells at an optimal Lovo flow rate of 40 mL/min. B2M editing efficiency was 50–60% across multiple timepoints (Day 4 and Day 7), maintained at 59–60% post-expansion at clinical scale.

CAR Cell Manufacturing: Today vs. Portal

Conventional Approaches

  • Viral vector manufacturing adds 6-12 months lead time and significant cost

  • Insertional mutagenesis risk with lentiviral and retroviral integration

  • Limited to single-construct delivery per viral vector

  • Electroporation causes 330+ misregulated genes and impaired cell expansion

  • Requires cell isolation, activation, and multi-day processing before engineering

  • Per-dose cost of approximately $95,780 limits patient access

Portal Mechanoporation

  • No viral vectors needed; deliver circRNA or mRNA directly to the cytosol

  • Zero misregulated genes at q<0.1 threshold; 16x better T cell expansion

  • Multiplex delivery of CAR + cytokines + gene edits in a single step

  • Engineer CAR cells from whole blood in under 10 minutes

  • Compatible with T cells, NK cells, and macrophages on the same platform

  • Projected ~90% cost reduction to approximately $10,000 per dose

Compatible Cargo for CAR Cell Engineering

Portal enables delivery of diverse cargo types to CAR cells, supporting both transient and permanent modifications.

circRNA

mRNA

CRISPR RNP

Cas9 Protein

siRNA

Plasmid DNA

Peptides

Antibodies

Small Molecules

Gatweay

Research Scale
  • Benchtop instrument for discovery research
  • 0.5-10M cells per run
  • 50-200 µl volume range
  • compact benchtop unit that fits in any hood
  • Available now
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Galaxy-i

High-Throughput Screening
  • High throughput scale instrument for screening applications with multi well plates.
  • 96/384-well plate compatibility
  • Integrate with existing automation
  • Ideal for DEL, PROTAC, crispr screening
  • Available now
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Millibooster

Clinical Manufacturing
  • GMP-ready clinical production system
  • 1 billion+ cells/minute throughput
  • Attach to existing equipment via tube-weld or luer lock connection
  • 2-100mL volume range
  • Available Now
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Ready to Build Better CAR Cells?

Whether you are engineering CAR-T, CAR-NK, or CAR-MAC cells, Portal's platform adapts to your workflow. Let us help you evaluate mechanoporation for your construct and cell type.