AAV is a workhorse for in vivo gene delivery, but its ~5 kb cargo limit forces hard tradeoffs that can make or break a program. This white paper breaks down dual- and triple-vector designs used to push past that ceiling, how cells reassemble split payloads, and what can go wrong when genomes truncate or capsids run empty. It also highlights why QC is not a box-checking exercise: small impurities or mapping errors can change expression, potency, and in vivo behavior. For teams building oversized cassettes, this paper offers both a roadmap and a risk check grounded in Vector Biolabs experience.
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