Optimizing Injectability of High-Viscosity Biologics In Next-Generation Syringe-Based Autoinjectors

Autoinjectors (AIs) integrated with prefilled syringes remain a preferred option for single-dose subcutaneous delivery, supporting the shift from hospital-based treatment to patient self-administration. Historically, most AI platforms were developed around 1mL long syringes; however, today’s higher-concentration biologics often require larger-volume containers (e.g., 2.25mL).

As product complexity grows, tight alignment between formulation, container, and delivery device becomes essential. Next-generation combination products must broaden their design space to maintain consistent performance against these evolving technical requirements.

In a collaborative study, Stevanato Group and Ypsomed investigate key drivers of injectability through two complementary experiments. The first evaluates the combined effect of increasing formulation viscosity and reducing needle length. The second examines how siliconization technology (sprayed-on versus cross-linked) influences force evolution over time, using accelerated aging to capture changes in performance.

This system-level approach helps guide component selection, reduces development risk, and supports robust, patient-centric autoinjector solutions tailored to next-generation therapeutic modalities.