Effect of air pockets in drug delivery in jet injections

Needle-free jet injections are actuated by a pressure impulse that can be delivered by different mechanisms, and the resultant jets are (10 2 ) m/s. Here, we report on the effect of entrapped air bubbles since filling procedures for pre-filled ampoules can induce bubbles, especially for viscous fluids. We use spring-piston devices as the principal actuation mechanism and vary both the location and size of the initial bubble. We find that the bubble location does have a statistically significant ( p < 0.05) effect on the jet exit speed, based upon the volumetric flow rate. However, we reveal subtle features such as intermittent atomization when the gas pockets pass through the orifice and de-pressurize, which leads to spray formation and a temporary increase in jet dispersion, both of which can lead to product loss during an injection. These results have implications for the development of prefilled ampoules for jet injection applications.