United States Single-use Bioreactors Market Assessment, By Product, By Type of Module, By Cell Type, By Application, By End-user, By Region, Opportunities and Forecast, 2018-2032F

United States single-use bioreactors market is projected to witness a CAGR of 17.98% during the forecast period 2025-2032, growing from USD 1271 million in 2024 to USD 4771.04 million in 2032. Growing demand for biologics and personalized therapeutics is fueling the adoption of single-use bioreactors in the United States market. Their flexibility, reduced risk of cross-contamination, and lower capital investment make them ideal for modern bioproduction. Advances in automation and continuous bioprocessing technologies further amplify their role in improving scalability and efficiency.

For instance, in January 2025, Danaher announced a strategic investment in Innovaccer Inc., a healthcare artificial intelligence company. This partnership aims to enhance patient outcomes by integrating Danaher's diagnostic technologies with Innovaccer's AI-driven unified patient records platform, facilitating the adoption of precision medicine and value-based care.

Rising Demand for Biopharmaceuticals and Personalized Medicines

The increasing demand for biopharmaceuticals and personalized medicine is significantly boosting the United States single-use bioreactors market. As healthcare providers and pharmaceutical manufacturers shift toward more targeted therapies such as monoclonal antibodies, gene therapies, and vaccines, the need for flexible and scalable bioreactor systems has grown. Single-use bioreactors are ideal for producing smaller, more customized batches while reducing cross-contamination risks and operational turnaround time. This demand is particularly evident in the development of advanced therapies such as antibody-drug conjugates (ADCs), which require precise and contamination-free production processes. The biopharma industry is also investing in smaller, decentralized facilities that can accelerate time-to-market for personalized treatments, which single-use systems can efficiently support. Moreover, regulatory bodies are promoting flexible production systems that can easily be validated and scaled. The integration of automation, data analytics, and smart monitoring in single-use bioreactors further enables more efficient and reproducible outcomes. Companies are now designing reactors tailored for specific therapeutic classes, supporting greater innovation in manufacturing. For instance, in September 2024, MilliporeSigma, the U.S. and Canada Life Science business of Merck KGaA, launched the Mobius ADC Reactor-specifically engineered to manufacture antibody-drug conjugates, addressing the growing demand for targeted cancer therapies.

Advancements in Bioprocessing Technologies

Technological advancements in bioprocessing are transforming the single-use bioreactors landscape, particularly in the United States market. Innovations such as continuous bioprocessing, perfusion systems, and improved sensor technologies are enabling more efficient, scalable, and cost-effective biopharmaceutical production. Single-use systems integrated with automation and advanced control platforms allow real-time monitoring and process optimization, which enhances reproducibility and ensures regulatory compliance. These developments are especially critical as the complexity of biologics increases, requiring highly controlled environments to maintain product integrity. Manufacturers are also prioritizing space-saving designs and modular systems, which make facility setup faster and more adaptable.

Furthermore, improvements in material sciences have enhanced the durability, sterility, and compatibility of disposable components, mitigating concerns about leachables or extractables. As companies aim to streamline product development timelines, scalable single-use bioreactors are becoming integral to both pilot and commercial production stages. These trends have made the United States a hub for innovation and adoption of next-generation bioreactors. For instance, in July 2024, Avantor launched two new high-performance reagents for gene therapy manufacturing: J.T. Baker Cell Lysis Solution and J.T. Baker Endonuclease. These reagents will improve the process efficiency and reduce the contamination risk.

Cost Efficiency and Lower Capital Investment

The usage of disposable bioreactors, known as single-use bioreactors, allows companies to minimize their expenses related to cleaning and sterilization operations. The cleaning process for traditional stainless-steel tanks requires substantial resources, including acidic solutions and steam sterilization. Without these steps, the investment expenditure can be reduced by approximately 40-50%. With the help of single-use bioreactors, manufacturers can quickly start their production activities without

incurring additional expenses while also optimizing their setup time to just hours. Additionally, the flexibility offered by single-use bioreactors allows manufacturers to adapt quickly to changing production needs, aiding them in avoiding the high costs associated with revalidating fixed systems. Thus, providing overall savings in labor, energy, and time to small-to-medium-scale biomanufacturing companies. In March 2025, Merck has opened a new USD 1 billion, 225,000-square-foot vaccine manufacturing facility in Durham, North Carolina. This state-of-the-art facility incorporates advanced technologies including data analytics and generative AI to enhance vaccine production.

Future Market Scenario (2025-2032F)

The United States single-use bioreactors market is poised for significant growth driven by increased biopharmaceutical production, the rising prevalence of chronic diseases, and a growing emphasis on cost-effective, flexible manufacturing solutions. The expansion of cell and gene therapies, along with personalized medicine, will continue to demand scalable and sterile environments provided by single-use systems. Furthermore, ongoing innovation in bioprocessing technologies, regulatory encouragement for agile production methods, and the presence of major industry players investing in R&D are expected to accelerate market adoption. The shift toward decentralized and modular biomanufacturing will further support widespread implementation of these bioreactors across the country.

Key Players Landscape and Outlook

The key players in the market are significantly investing in the development of single-use bioreactors and are utilizing strategies such as mergers, acquisitions, partnerships, and new product launches to improve their services and competitiveness. Such efforts will propel significant growth in the market, allowing large-cap industry players to increase their presence and, therefore, find new opportunities in this market.

In February 2025, Thermo Fisher Scientific entered into an agreement to acquire Solventum's Purification and Filtration business for USD 4.1 billion in cash. This acquisition will enhance Thermo Fisher's bioproduction capabilities, particularly in biologics manufacturing, by integrating Solventum's innovative filtration technologies. The deal is expected to close by the end of 2025.