Thermostable unit solid dose formulations for subcutaneous administration of DNA vaccines.

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2025

Molecular Therapy Nucleic Acids (2025), doi: https://doi.org/10.1016/j.omtn.2025.102628.

Thermostable unit solid dose formulations for subcutaneous administration of DNA vaccines.

Pablo Garcia-Valtanen, Arthur Eng Lip Yeow, Zelalem A. Mekonnen, Dawn M. Whelan, Ryan Santos, Zahraa Al-Delfi, Susana Rodrigues, Pauline Gavan, Keith Howard, Makutiro G. Masavuli, Branka Grubor-Bauk

Viral Immunology Group, Discipline of Surgery, The Basil Hetzel Institute for Translational Health Research, The University of Adelaide, Adelaide, 5011, South Australia, Australia Instituto de Investigación, Desarrollo e Innovación en Biotecnología Sanitaria de Elche, Universidad Miguel Hernández, 03202, Elche, Spain aVaxziPen Ltd., 120 A&B Olympic Avenue, Abingdon, OX14 4SA, United Kingdom These authors contributed equally as first authors. These authors contributed equally as senior authors.

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Abstract

The COVID-19 pandemic has highlighted the critical need for thermostable vaccines to ensure equitable distribution and accessibility, particularly in regions lacking cold-chain infrastructure. Here we present a thermostable, solid dose DNA vaccine (SDV) platform for subcutaneous delivery, based on a sugar–sugar alcohol–polymer formulation manufactured via lyophilization and compaction. Using luciferase (Luc) expressing plasmid as a model, we demonstrate that subcutaneous vaccination with SDV formulation of C57BL/6 mice results in efficient and durable transgene expression in vivo. In vitro stability assays confirmed that the SDV formulation maintained excellent thermostability after 30 days of storage at 4°C, 25°C, 37°C and 42°C. We next applied the SDV platform to a Zika virus (ZIKV) NS1 DNA vaccine and immunized BALB/c mice. ZIKV-SDV vaccination elicited robust NS1-specific antibody and T cell responses, and conferred protection following ZIKV challenge. These data establish the feasibility of lyophilized SDV DNA vaccines for needle-free thermostable delivery. By eliminating the need for reconstitution, refrigeration and skilled administration, SDV formulation has the potential to enhance the deployment, cost-effectiveness and shelf life of DNA vaccines in resource-limited settings.

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