A stopper includes a main body portion defining an open rearward end configured to receive the plunger rod, an engagement portion provided along an inner circumference of the main body portion configured to engage at least a top portion of the plunger rod, a closed front end forming a flexible roof, and a first perimetrical skirt extending around an outer circumference of the main body portion toward the closed front end of the main body portion. When fluid pressure is increased inside the syringe barrel during an injection, the flexible roof expands in a radial direction toward an inner wall of the syringe barrel, the first perimetrical skirt is forced against the inner wall of the syringe barrel, and an engagement between the plunger rod and the engagement portion forces the main body portion to expand in the radial direction toward the inner wall of the syringe barrel.

A method of manufacturing a cartridge is described. An injection needle is inserted into a mold that forms a barrel. The barrel defines an open proximal end, an opposing distal end, an internal reservoir therebetween, and an arm projecting distally from the distal end of the barrel and having a portion bent at a fixed angle. The injection needle is positioned within a portion of the mold configured to form the arm of the barrel, and a terminal needle tip is oriented such that a beveled opening of the needle tip is distally facing. The injection needle is stabilized against movement with a gripping device. The mold is filled with resin to form the barrel around the injection needle. The gripping device is separated from the injection needle upon hardening of the resin.

Drug delivery systems with reduced hold-up volumes are provided. The drug delivery systems include a cartridge configured to hold a liquid drug. A cartridge stopper is positioned in a first portion of the cartridge. A needle guide component is positioned within the cartridge stopper. A needle is positioned within a central opening of the needle guide. A plunger is positioned in a second portion of the cartridge. The plunger includes a fluid path pocket facing and aligned with the central opening of the needle guide component. The plunger is driven toward the cartridge stopper to expel the liquid drug from the cartridge through the needle. An end of the needle can be positioned within the fluid path pocket when the plunger is pushed against the cartridge stopper, ensuring that only a small volume of the liquid drug remains in the cartridge when delivery of the liquid drug is completed.

The invention relates to a method for reducing an amount of sub visible particles in a pharmaceutical composition contained in a medical injection device comprising a container (1) including a barrel (10) lubricated with a lubricant coating (2) in contact with the pharmaceutical composition, and a stopper (14) in sliding engagement within the barrel (10), the container comprising a region (130, 121, 123) extending distally from the distal end (100) of the barrel which is not accessible to the stopper. During formation of said lubricant coating (2) on the inner wall of the barrel, the method comprises limiting lubricant from being deposited into said region (130, 121, 123) extending distally from the distal end (100) of the barrel.

A prefilled syringe and a method of filling a syringe with a pegfilgrastim solution to provide a target extracted volume of pegfilgrastim solution from the syringe are described. A method includes selecting the target extracted volume of pegfilgrastim solution, determining an estimated drug transfer loss, determining an estimated syringe dead volume, filling the syringe with a volume of pegfilgrastim solution comprising at least the target extracted volume plus the estimated drug transfer loss plus the estimated syringe dead volume.

A syringe type ejection device capable of reducing an amount of residual liquid is provided. A syringe type ejection device includes: a barrel; a nozzle disposed to face the barrel; and a core inserted in the nozzle, the barrel having a large-diameter portion provided with a discharge space for discharging liquid, the nozzle being provided with a holding space for holding the core, the holding space being in communication with the discharge space, and the core being inserted in the discharge space.

A method of inserting a lubricant free stopper into a lubricant free syringe barrel or lubricant free cartridge tube is disclosed. The method includes (1) inserting a stopper with a sealing rib into a placement region of a hybrid insertion device, (2) lowering the body of the hybrid insertion device into a syringe barrel or cartridge tube to a position located past the barrel flange or top of the cartridge tube while stablishing a sealable connection with the syringe barrel or cartridge tube, (3) maneuvering the stopper past the distal opening of the hybrid insertion device using an insertion pin and deploying the stopper at a final position within the syringe barrel or cartridge tube under vacuum assistance, (4) fully retracting the insertion pin from the syringe barrel or cartridge tube, and (5) retracting the hybrid insertion device from syringe barrel or cartridge tube. The method is lubricant free or substantially lubricant free. The hybrid insertion device may be electropolished and/or extrude honed.

Medical device assemblies capable of aspirating liquid into a syringe barrel or other medical devices while evacuating any air from the syringe are described. An exemplary medical device includes a syringe barrel, plunger rod and stopper assembly having an air permeable and liquid impermeable porous portion and structure for forming a vacuum within either the stopper or the plunger rod. Described is a medical device including a syringe barrel, plunger rod and stopper assembly having an air permeable and liquid impermeable porous portion and structure for forming a vacuum within chamber between the stopper and plunger rod wherein the plunger rod includes a sealing edge and is moveable relative to the stopper. Exemplary medical devices may include a vent for allowing air that permeates through the porous portion to escape to atmosphere. Methods for aspirating a syringe barrel with a liquid are also provided.

The present disclosure relates to a stopper configured to be positioned inside a barrel of an injection device for injecting at least one composition, said stopper including: a gasket including a proximal end, a distal end, a lateral wall, and a through hole extending from the proximal end to the distal end, an insert inserted in the through hole, wherein the stopper is adapted to deform between: a closed configuration wherein the gasket cooperates with the insert to hermetically close the through hole, for preventing flow of the composition between the proximal end and the distal end of the gasket, and an open configuration wherein the gasket cooperates with the insert to open a fluidic pathway in the through hole between the proximal end and the distal end of the gasket for allowing flow of the composition

An example syringe includes a barrel having a distal end region and an inner surface defining a lumen extending therein, wherein the inner surface includes a proximally facing surface, and wherein the distal end region includes a distal end. The syringe also includes a plunger having a body portion and a distal tip extending distally away from a distal end region of the body portion, wherein the distal end region includes a distally facing surface. Further, the plunger is configured to be positioned within the lumen of the barrel and a portion of the distal tip of the plunger extends distally of the distal end of the barrel when the plunger is positioned within the lumen of the barrel.