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Impact of Incomplete Plunger Rod Engagement on the Functionality of Prefilled Syringes
Yuan Zhou, Wei Chen, Junwei Wang, Qian Jiao, Zhixin Zhao*, Jeremy Guo*

Prefilled syringes (PFSs) are critical for parenteral drug delivery, where precise assembly is essential to safety and performance. Although manufacturing typically emphasizes filling and stoppering, incomplete plunger rod insertion is often overlooked. This study investigates the impact of varying rod–stopper gap (RSG) levels on syringe functionality across different solution viscosities. Results show that even small RSGs reduce and delay break-loose force, disrupt stopper gliding, and increase rod detachment risk during use or transport. Larger gaps further compromise reliability by weakening rod engagement. These findings highlight the need for complete rod insertion and stricter process controls to ensure PFS integrity and patient safety.

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