Presented herein is a description for the manufacturing of inactivated HIV for use in vaccines against AIDS, as well as other inactivated viruses for other infectious diseases. This invention incorporates methods for inactivating infectious virus particles while retaining protein integrity and antigenicity. The methods utilize critical, near-critical or supercritical fluids with or without polar cosolvents. This invention would allow for the creation of HIV vaccines from genetically attenuated HIV strains for a greater degree of product safety, and from combinations of different HIV strains for broader protection. This HIV vaccine manufacturing technology is inexpensive, amenable to large-scale processing and portable, i.e. it can be readily implemented in a host country site. This invention can be utilized for other viral and bacterial infectious diseases, such as influenza and hepatitis.