Injection Needle Cap Removal Tools

Instron | Autoinjector | Provisional Patent

Overview

I developed a universal cap removal set designed to accommodate a wide range of autoinjector pens. The modular system enables quick swapping of attachment plates, supporting critical tasks such as cap removal, device positioning, and injection operations, enhancing flexibility and efficiency during testing.

 

Solutions

  • Durable Design: Upgraded from 3D-printed to machined components for enhanced durability and scalability.

  • Versatile Compatibility: Standardized geometry to support up to “80” device configurations.

  • Customizable Features: Added mounting holes for custom inserts and ESG-compatible attachments.

  • Modular Base: Enabled quick swapping of attachments for multi-functional testing.

Challenges

  • Standardize custom cap removal solutions into a versatile product.

  • Ensure vertical alignment of test space and components.

 

Analysis & Validation

FEA ❖ Design Validation Testing ❖ GD&T

Design & Development

Concept Generation ❖ CAD ❖ Prototyping ❖ DFM ❖ DFA

Manufacturing

Material Selection ❖ Supplier Coordination

Communication

Cross-Functional Collaboration ❖ Client Interaction ❖ Documentation

3D Printed to Machined

The cap removal fixtures were initially 3D-printed to meet the custom-fit requirements for specific devices. The challenge was to replicate their functional design while transitioning to a machinable solution. By redesigning the components for AISI 303 stainless steel, I delivered a scalable, durable, and aesthetically refined product that met functional and production requirements.

 

Multi-purpose Attachments

The default attachments are versatile, functioning as cap removal edges or syringe-holding fixtures. The base design is simple and reusable, allowing ESG teams and customers to attach additional components for other functions. This modular approach supports virtually limitless customization options.

 

Easy to assemble

The design incorporates alignment pins and thumb screws to facilitate quick and secure plate swapping. This simplifies transitions between testing different devices or specific functions, saving time and ensuring consistency.

 

Analysis

Finite element analysis (FEA) was conducted to assess the safety and performance of the cap removal attachments under operational stresses. Simulations modeled the forces experienced when pulling an autoinjector upward, evaluating factors of safety, and optimizing plate thickness, hole location, geometry, and material selection to ensure durability and reliability.

 

Final Product

Impact:

  • Faster Setup: Reduced time required to switch between testing new devices and functions.

  • Scalable Design: Converted custom 3D-printed parts to standardized machined components for broader usability.

  • More Accurate Data: Eliminated pre-loading of specimen caps to obtain more representative testing data.

  • Efficient Adaptability: Minimized engineering time and cost to accommodate new autoinjector types.

  • Future-Proofing: Added flexible mounting points to support future ESG requirements.