Intelliject Auto-Injector Case Study

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Auto-injector uses Covestro thermoplastics for optimal portability, safety

A pharmaceutical company was searching for materials to mold the housing and outer cover of its epinephrine auto-injector. The thermoplastics to be used needed to have high flow to fill the thin-wall parts, as well as provide high strength and be available in various colors. The thermoplastics also needed to meet biocompatibility requirements.

OEM: Pharmaceutical Company
Industry: Medical
Application: Epinephrine auto-injector
Product: Makrolon® 2458 medical-grade polycarbonate
                Bayblend® (PC+ABS blend) M850 and M850XF

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The specialty pharmaceutical company selected medical grade polycarbonates and polycarbonate blends from Covestro to mold several parts of its epinephrine auto-injector, which is the size of a credit card and thinner than a typical cell phone. The device is designed for patients at risk for anaphylaxis, or severe allergic reaction.

Makrolon® 2458 medical  grade polycarbonate was chosen for the very thin outer cover because, as a high-flow resin, it is the ideal material for thin-wall molding.

The electrical cover, white housing, top and red safety guard are injection molded using two medical grades of Bayblend® (PC+ABS blend) – Bayblend® M850 and Bayblend® M850XF.

The part of the device that touches the patient during injection is molded from Bayblend® M850XF. These medical grades of Bayblend® meet the requirements of the FDA-modified ISO 10993-1 tests for biocompatibility while offering impact resistance and rigidity, a palette of colors that meet biocompatibility requirements, as well as dimensional and color stability.

In addition to supplying materials, Covestro provided technical support throughout the device’s development, conducting finite element analysis and mold-flow analysis of the materials.

The main properties of Makrolon® medical polycarbonate grades are:

  • Transparency and custom colorability 
  • High impact strength
  • Durability
  • Able to be sterilized
  • Satisfies major bio-compatibility requirements
  • Resistant to many pharmaceuticals 

The main properties of Bayblend® M850 and Bayblend® M850XF resins are:

  • High toughness even at low temperatures
  • Heat resistant up to 142ºC (Vicat B/120)
  • High dimensional accuracy and stability
  • Good flowability
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