BD, Ypsomed to develop 5.5 mL autoinjector-compatible syringe

BD and Ypsomed are extending their long-standing collaboration with the development of a 5.5 mL glass prefillable syringe designed for compatibility with an established large-volume autoinjector platform. The initiative addresses increasing demand for subcutaneous self-administration of high-dose biologics.

The new syringe configuration is intended for applications requiring injection volumes above 1 mL, where higher formulation viscosity and extended injection times present technical and usability challenges. To address these constraints, the design incorporates an 8 mm needle and thinner wall cannulas to improve flow characteristics and reduce resistance during delivery.

Large-volume subcutaneous delivery is increasingly relevant across therapeutic areas such as oncology, autoimmune disorders, rare diseases and metabolic conditions. In these use cases, injection time, patient comfort and device reliability are key parameters influencing adherence and clinical outcomes.

The syringe has been developed to integrate mechanically and functionally with an existing 5.5 mL autoinjector platform introduced in 2022. The platform supports two-step activation, ergonomic handling and user feedback mechanisms, enabling self-administration outside clinical settings.

This latest development builds on earlier joint work involving a 2.25 mL syringe–autoinjector combination, which demonstrated improved flow performance across a wide viscosity range, including formulations up to 70 cP¹. The 5.5 mL format extends this approach to higher-dose therapies, supporting combination product development and reducing engineering rework during late-stage drug development.

The 5.5 mL glass prefillable syringe is currently under development and will undergo compatibility and performance testing with the corresponding autoinjector. Feasibility study samples are planned for availability in mid-2026, alongside platform updates to support integration.

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