SUMMARY

Significant potential for plastic hypodermic needles exists as an alternative to current steel needles, especially in developing regions where proper needle disposal is problematic. This thesis presents the design and testing of one type of plastic hypodermic needles. The buckling and penetration characteristics of the needles were modeled and analyzed analytically and by finite element analyses. Experimental penetration tests using steel and plastic hypodermic needles and skin mimics, specifically polyurethane film and pig skin, were performed to determine penetration and friction forces. Penetration tests were also conducted using butyl rubber to determine whether the needles could penetrate rubber stoppers that cover drug vials. Various lubricants, including silicone oil and a medical grade silicone dispersion, were also used. In addition, the needles underwent perpendicular bending tests and cannula stiffness tests. Finally, fluid flow tests were conducted to determine fluid flow rates through the needles. Experimental results were compared to each other and finite element analyses and discussed. The research presented in this thesis demonstrates that with further design modifications, plastic needles may become suitable for mass replacement of steel needles, thus helping to eradicate the many health and environmental risks brought upon by steel needles.