Drug delivery hero

MARKETS

Drug Delivery Devices

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WHO ARE WE

Drug Delivery Devices

Carclo is a trusted partner in the design, development and manufacture of drug delivery devices that patients and clinicians rely every hour of every day. Over two decades, our teams have supported global pharmaceutical leaders with precision-engineered components and assemblies for inhalers, auto-injectors, and injection pens — devices where safety, performance and patient confidence are non-negotiable.

What we make

Carclo delivers precision components and assemblies across a broad range of drug delivery devices, including inhalers, auto-injectors and associated delivery systems.

Within LifeTech Solutions, our focus now extends to development of next-generation drug delivery hardware:

  • simplified, patient-friendly two-stage auto-injectors
  • disposable and reusable pens for biologics or frequent-use therapies
  • integrated inhaler development
  • Combined with our ambition to drug delivery devices with smart patient friendly capabilities

Carclo is an innovation partner capable of supporting both legacy programmes and future proprietary device development.

How we make it

Drug delivery devices require consistent part performance, tight tolerances, robust materials, and often clean- processing or controlled environments. Carclo delivers through:

  • Regulated, high-precision manufacturing
  • Controlled cleanroom
  • Multipart injection moulding + assembly + decoration
  • Flexible manufacturing footprint

With facilities in UK, EU, US and Asia, we support global supply chains and scale-up for high-volume drug delivery programmes.

The same capability platform that supports legacy inhalers and auto-injectors now underpins LifeTech’s early-stage device innovation — from concept through validation and volume manufacturing readiness.

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Materials

Drug delivery devices demand materials and processes that meet high regulatory, safety and functional standards. Carclo typically works with:

  • Polypropylene (PP) — for housings, pen bodies and many structural components
  • Polycarbonate (PC) / PC-blends — for transparent parts, mechanisms requiring high strength or clarity
  • ABS — for robustness and surface finish on housings and external covers
  • Polyethylene variants (HDPE/LDPE) — for container or closure elements,m
  • Elastomers / TPEs — for seals, soft-touch surfaces, ergonomic grips
  • Specialty polymers — when chemical resistance, barrier properties or low-friction surfaces are required

 

Typical Programmes

Typical programmes include:

  • Supply of inhaler and injection-device components & assemblies
  • High-volume manufacture of auto-injector disposable pen components and assemblies.
  • New concept development work under LifeTech Solutions: two-stage auto-injectors, disposable or reusable pens, device ergonomics and human factors design, patient-centric devices
  • Integration of smart connected device features as part of future drug-device combination products

Core Drug Delivery Device Capabilities

  • ISO 13485–aligned medical manufacturing for drug-device combination products

  • Precision injection moulding, multipart tooling and high-cavitation production for pens, inhalers, auto-injectors, device housings and internal mechanisms

  • Cleanroom manufacturing for inhalers or other devices with sterile or particulate-sensitive components

  • Automated assembly, decoration, part inspection and packaging for large-scale device programmes

  • Global manufacturing footprint — UK, Europe, US, Asia — enabling regional supply and risk-managed production scaling

  • Capability to support both legacy OEM device production and new device concept development under LifeTech Solutions

innovation

Recent Investments

Carclo has made several investments that directly strengthen our Drug Delivery Device capability:

  • Cleanroom expansions in both the US and Europe, supporting drug delivery components.
  • New all-electric injection moulding machines providing the stability needed for tight-tolerance parts.
  • Ongoing collaboration with major OEMs that drives continuous improvement in component performance and manufacturability.
  • Enhanced materials and analytics capability
  • LifeTech Solutions incubator providing a framework to channel future Drug Delivery innovation — our SYNCURA digital companion.

Why it matters

Drug delivery devices — pens, injectors, inhalers — are the critical interface between drug formulations and patients. Their design, reliability, usability and manufacturability directly impact therapy success, adherence, safety and scalability.

Carclo’s strength in this space matters because:

  • We enable pharmaceutical companies to bring therapies to market with robust, high-quality delivery systems.
  • Our history with inhalers and auto-injectors demonstrates proven capabilities.
  • We support a range of parenteral delivery formats providing flexibility across therapy types.
  • We create the bridge between legacy manufacturing and future-facing device innovation under LifeTech Solutions.
  • Through initiatives like two-stage auto-injectors, re-usable/disposable pens, and eventually connected devices, we aim to deliver patient-centric, next-generation drug delivery solutions.