The client provided an early-stage concept of a new auto-injector platform but needed to reduce the device diameter, component complexity and part count too. The deliverables were to develop a less complex, more robust design which could be manufactured in volumes up to 50 million units per annum.
HD’s approach began by thoroughly reviewing the early-stage platform concept to identify perceived issues and opportunities for improvement. From here, we began developing more sophisticated concepts addressing the key requirements of;
• Reduced pen diameter.
• Less complexity with fewer interactions, to reduce tolerance stacks.
• Fewer components, to lower manufacturing costs.
• Capability of being manufactured in high volume, (Approx 50 million per annum.) with fully automated manufacturing and assembly.
With a number of strong concepts that met the above needs, we undertook a thorough concept review and began the detailed design, development and engineering of the chosen concept to a functional prototype level. This required robust design thinking to identify and analyse critical features and produce a component interaction matrix. We used Non-Linear FEA to test snap fits, clips and spring features with design optimisation to reduce diameter.