4We have produced a thermally stable recombinant human type 5 adenoviral vector 5 (AdHu5) through spray drying with three excipient formulations (L-leucine, lactose/trehalose 6 and mannitol/dextran). Spray drying leads to immobilization of the viral vector which is believed 7 to prevent viral protein unfolding, aggregation and inactivation. The spray dried powders were 8 characterized by scanning electron microscopy, differential scanning calorimetry, Karl Fischer 9 titrations, and X-ray diffraction to identify the effects of temperature and atmospheric moisture 10 on the immobilizing matrix. Thermal stability of the viral vector was confirmed in vitro by 11 infection of A549 lung epithelial cells. Mannitol/dextran powders showed the greatest 12 improvement in thermal stability with almost no viral activity loss after storage at 20°C for 90 13 days (0.7 ± 0.3 log TCID 50 ) which is a significant improvement over the current -80 o C storage 14 protocol. Furthermore, viral activity was retained over short term exposure (72 hours) to 15 temperatures as high as 55°C. Conversely, all powders exhibited activity loss when subjected to 16 moisture due to amplified molecular motion of the matrix. Overall, a straightforward method 17 ideal for the production of thermally stable vaccines has been demonstrated through spray drying 18AdHu5 with a blend of mannitol and dextran and storing the powder under low humidity 19 conditions. 20 21