Overview
Patients with chronic conditions often struggle with self-administered injections due to the dexterity required to manipulate small syringes. NOVO partnered with Unilife, a developer and manufacturer of single-use, prefilled, safety syringes, to develop an electronically controlled autoinjector — a novel device designed to improve ease of use and enhance patient experience.
Unlike traditional mechanical autoinjectors, this solution incorporated electronic controls, allowing for customizable dosing speeds, enhanced safety mechanisms, and improved user feedback. The result was a more intuitive, reliable, and patient-friendly device.
Key Engineering Challenges & Solutions
| Challenge | NOVO’s Solution |
|---|---|
| Complex Motor & Drive System Designed to remove the needle shield, advance the syringe, control plunger movement, and safely retract the needle. |
Developed a high-ratio, low-friction drive train coupled with a compact DC motor for precision control. Integrated an optical encoder for stability and reliability. |
| Battery Life Optimization Needed to function with a non-rechargeable battery for a total lifespan of 5 years (3-year shelf life + 2 years of use). |
Engineered low-power electronics, efficient mechanisms, and power management algorithms to maximize battery efficiency. |
| Handling Drugs of Varying Viscosities Required a drive system adaptable to different flow rates under varied conditions. |
Designed a variable-speed control system that adjusted dosing speed based on fluid viscosity, ensuring accurate and comfortable administration. |
| Miniaturization & Component Integration The device had to be sleek, compact, and ergonomic while housing electronic components. |
Developed custom firmware to control the process, enable the user interface, and manage error conditions. |
Human-Centered Design & User Experience Enhancements
NOVO collaborated with the client’s industrial design team to refine the device for usability and patient comfort. Key innovations included:
- Multi-Function Button with LED Indicators – Simplified operation with clear visual feedback.
- Skin Surface Detection – Prevented unintentional activation and conserved expensive medication.
- Customizable Dosing Speeds – Allowed users to select the injection speed most comfortable for them.
- Battery Life Indicator – Ensured users were aware of remaining battery capacity.
Results & Impact
- Enhanced Patient Experience – More intuitive and less intimidating than traditional syringes.
- Greater Safety & Compliance – Automatic needle retraction and interlock mechanisms reduced risk of misuse.
- Industry Recognition & IP Protection – Contributions resulted in U.S. Patents 8 979 795 and 8 939 935.
Why NOVO?
The global demand for smart autoinjectors has surged, with today’s platforms integrating Bluetooth connectivity, compliance tracking, data logging, and app-based feedback. While these innovations have only recently become mainstream, the device NOVO developed in collaboration with Unilife showcased forward-thinking design principles that would later become common in connected medical devices. NOVO provided engineering and technical design expertise to integrate electronic control, precision motor systems, and patient-centric features.
Our work on customizable dosing speeds, real-time feedback, and enhanced safety mechanisms helped demonstrate the feasibility and value of electronics in what was then an almost entirely mechanical product category. These foundational elements now serve as core features in next-generation injection systems.
As the market continues to evolve toward connected therapeutics and digital health integration, NOVO remains a trusted engineering partner – solving complex technical challenges and helping clients deliver devices that meet both patient needs and regulatory requirements.
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