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Our client faced a critical challenge, manufacturing defects in syringe needles, described as angling or hooking at the tips. This defect can occur during manufacturing or handling and can affect effectiveness of drug delivery and the needle's ability to puncture the skin smoothly making the injection more painful for the recipient. Detecting and addressing such defects is crucial to ensuring both the safety and efficacy, particularly in delicate applications like vaccine administration.
Needle hooking or angling are nearly invisible deviations which require high-powered microscopes for detection to quantify and observe the flaw reliably. With thousands of syringes in each batch, rapid and accurate assessment was crucial to provide confidence in the batch as a whole.
Detecting and addressing such defects is crucial to ensuring both the safety and efficacy, particularly in delicate applications like vaccine administration.
Needle hooking or angling are nearly invisible deviations which require high-powered microscopes for detection to quantify and observe the flaw reliably.
With thousands of syringes in each batch, rapid and accurate assessment was crucial to provide confidence in the batch as a whole.
Left: Example of hooked needle. Right: Example of bent needle
We partnered with the client to create a bespoke solution tailored to their needs and QA documentation. Using advanced high-magnification microscopes and cutting-edge calibrated imaging software, we developed a precise method for detecting these defects.
To aid with speed and consistency, we 3D-printed custom sample holders, designed to fit the exact dimensions of the clients’ syringes. This held the needles for imaging consistently each time.
Paired with a semi-automated motorised microscope stage, we were able to quickly inspect hundreds of needles to an accuracy of several microns, ensuring consistent, reliable results for batch release.
Our tailored approach delivered the speed, precision, and confidence our client needed to maintain the highest quality standards.