Designing drug delivery devices for ultra high-volume production
Scaling production reveals issues hidden below the surface in prototypes and DVT. Rare failure modes, sensitivity, and long-tail performance issues emerge as volume grows. RD8 helps teams eliminate these risks early - avoiding late delays, costly surprises, and non-conformities in mass production.
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High-volume production exposes sensitivities that smaller scale volumes rarely reveals. Without the right approach, teams face unexpected failures and escalating costs.
RD8’s approach to de-risking ultra high-volume production
Our methods systematically increase predictability, reduce variation sensitivity, and embed manufacturability into the design - ensuring devices scale reliably.
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Increase Predictability - Eliminate Failure Modes
Complex architectures can hide failure modes that only appear at scale. We use Robust Design principles to improve interface design, simplify tolerance chains, and remove superfluous specifications — increasing predictability and enabling faster, more confident decision-making.
Reduce Variation Sensitivity - Control Scaling Risk
As production ramps up, variation multiplies. We work with your tolerance management system (or provide our proven framework) to minimise sensitivity and ensure designs can absorb unavoidable variation — reducing scaling risk and keeping production stable.
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Inherent Performance by Design - DfM for High-Volume Injection Moulding
Optimising functionality and design for manufacturability must happen in sync. Using Robust Design principles, we preserve critical functional surfaces while optimising for high-volume injection moulding. This reduces costly iterations and embeds reliability directly into the design.
Is your device ready to scale without surprises?
Not every design is built for the manufacturing volumes your business needs today. If scaling is your next step, let’s discuss whether RD8’s approach is the right fit to secure reliability at scale.
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