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Case Study - Ellipta Dry Powder Inhaler

The extensive relationship with this client in which Warwick Design had carried out extensive design, R&D and industrialisation developed a high level of confidence, ease of communication with an understanding of the partner’s rigorous requirements.

The inhaler was designed to work consistently and reliably over a much wider dimensional tolerance band for the components than will ever be seen. The design therefore is extremely robust in use and the device has considerable manufacturing resilience.

Warwick Design contributed to the IP in the inhaler and was responsible for the the major portion of the design and detailing. Prototype steel tooling was manufactured from early development data enabling evaluation of the device’s performance and potential production requirements from first-off sample mouldings. The refinement continued leading to Warwick Design providing component data for the clinical trial mouldings, industrialisation and scaleup stages. This was a highly collaborative project with weekly meetings attended by all partners involved.

The device was conceived for straightforward open-inhale-close operation with a large character decrementing dose counter to provide the user with a clear indication of the remaining treatments.

This complex highly reliable device represents eight years of development. during which we undertook:

layout concept
innovation,
experimentation,
IP generation
detail design
component design
design for scale up
industrialisation

Prototype steel tooling was manufactured from our early development data enabling evaluation of the device’s performance and potential production requirements from first-off sample mouldings.

The refinement continued leading to Warwick Design providing component data for the clinical trial mouldings, industrialisation and scaleup stages. This was a highly collaborative project with weekly meetings attended by all partners including Tech Group, Männer, Rexam and GSK’s own teams.

Warwick Design also supported this device with assembly rigs that ensure pre-production quantities are put together correctly allowing the function of clips and welds to be assessed.

Specialised test and assembly equipment can be provided for some of the manufacturing operations. By Warwick Design providing these supplementary services in-house the client has benefitted from a quicker turnaround, with reduced knowledge transfer issues and number of external suppliers kept to a minimum.

Warwick Design also supported this project with strip making machines for laboratory scale strip manufacture.

Warwick Design is involved in usability trials, various FMEAs etc.

We supply data directly to toolmakers and have very good relationships with high quality suppliers like Männer, Schotlii, Avenue Mould & Tool.

Ellipta is the property of GSK