This thesis proposes the YpsoMate Refill concept design: an autoinjector that can be refilled at a Refill Hub to reduce its environmental impact. After five reuses, it has a 60% lower CO2e impact than the single-use YpsoMate. The concept design aims to inspire the non-profit Alliance to Zero in their journey towards a sustainable pharmaceutical sector.

The YpsoMate autoinjector is a popular and convenient self-injection device used for various conditions, but its single-use design generates a significant amount of waste and CO2 emissions. To turn this wasteful linear life cycle into a circular one, this report analyses current autoinjectors on their ease of disassembly and their environmental impact, using tools like HotSpot Mapping, Disassembly Maps, and Life Cycle Assessments.

The project’s outcome is a visionary concept design for transitioning autoinjectors into the Circular Economy – the YpsoMate Refill. The proposal includes interventions to reduce the part count from 19 to 17 to minimize CO2e emissions. Moreover, it contains a new product architecture that enables quick and easy automated dis- and reassembly for reuse. Additionally, the use of a limited amount of commonly recycled bio-based plastics supports recycling at the end of life.

The circular product life cycle involves returning the used autoinjector at a Refill Hub, where it undergoes automated disassembly, disinfection, replacement of the prefilled syringe, a rigorous quality check, and reassembly. Finally, it is sealed with a new medicine-specific label to provide patients with a fresh and trustworthy product.

A Life Cycle Assessment (LCA) confirms that even if the YpsoMate Refill is not reused, its environmental impact is approximately 25% lower (excluding the use-phase) than the single-use YpsoMate. This is thanks to the use of bioplastics and its reduced part count. Moreover, the LCA shows that the YpsoMate Refill emits approximately 50% less CO2e than the single-use YpsoMate after one reuse (two use-cycles) and approximately 65% after five reuses.

Compared to the single-use YpsoMate, the YpsoMate Refill is much easier to dis- and reassemble. While I had to break parts of the single-use YpsoMate during disassembly, the YpsoMate Refill features reusable connections. Due to its subassemblies, it requires only three steps to reach any part in the YpsoMate Refill, in comparison to nine steps for the single-use YpsoMate. Moreover, the entire device can be disassembled in eight tasks, compared to the twenty-one tasks required for the single-use YpsoMate.

In conclusion, the YpsoMate Refill concept offers a sustainable, convenient, and safe alternative to single-use autoinjectors. It aims to inspire the non-profit Alliance to Zero in their journey towards a sustainable pharmaceutical sector and provides patients with the opportunity to take care of their health without harming the environment.