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The Client

Zogenix, a pharmaceutical commercial leader, now owns the finished products and have used them in the SUMAVEL® DosePro™ (sumatriptan injection) Needle-free Delivery System which was launched in January 2010.

The Challenge

Dalau™ Ltd was approached by designer Simon Weston of Weston Medical Ltd to manufacture machined components for the prototyping of the first needle-free system for subcutaneous delivery of sumatriptan, used for the treatment of acute migraine and cluster headache.

Our brief was to develop and produce a piston component that could withstand high pressure impact from the plunger, operate in all climate conditions and pass the stringent FDA requirements. It had to have a high surface finish ensuring ease of piston movement within the Intraject system, but also required a lip seal form and shape to deal with potential temperature fluctuations during its use – the seal would prevent drug leakage enabling the prescribed drug dosage to be delivered correctly and consistently time after time.

Our Solution

dalau™ Ltd successfully co-designed and manufactured the bespoke component required, in a clean room environment.


Chris Keenan, from Aradigm, Pharmaceutical Company, confirmed that “working with a ‘best in class’ manufacturer like dalau™ Ltd has allowed us to consistently exceed expectations for innovative product solutions in the area of drug device development”.

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