Effect of Driving Pressure Modes on Microjet Dispersion Characteristics in Tissue-Mimicking Gels for Large-Volume Needle-Free Injection

Needle-free injection (NFI) technology is a promising alternative to conventional syringe injection, as it mitigates needle-related complications and enhances patient compliance. However, achieving the controlled and efficient dispersion of larger-volume formulations (>1 mL) within tissues remains a significant challenge. This study presents a novel pneumatic NFI system that uses a two-phase driving mode to regulate driving pressure and duration with an ejection volume of 1.0-2.0 mL. The integrated pressure stabilization unit significantly reduces pressure fluctuations during the initial injection phase, generating a more stable and uniform spray distribution. It is designed to produce an ideal elliptical dispersion effect while eliminating splatter, enabling controlled large-volume delivery. Jet impact experiments were conducted to investigate the dynamic characteristics of microjets generated by conventional single-phase and novel two-phase driving modes. Furthermore, the influence of the driving mode on the dispersion behaviors of microjets in agarose gels was explored through high-speed imaging of gel injections. The results demonstrate that the two-phase driving mode produces a distinct two-phase jet pressure profile. Compared to the single-phase mode, the two-phase mode produced a significantly larger dispersion width at equivalent initial driving pressures. This promotes more uniform lateral drug distribution and achieves a higher percentage of liquid drug delivery in gels. Furthermore, favorable driving pressure combinations were identified for different volumes: (1.25-0.25) MPa for 1.0 mL, (1.25-0.50) MPa for 1.5 mL, and (1.50-0.50) MPa for 2.0 mL. This provides a practical basis for optimizing clinical parameters and advancing the development of controllable NFI systems.