Hypodermic needles are widely used in both medicine and dentistry, which makes their study crucial. Understanding the pain perception caused by the insertion of these needles is particularly important for patients who fear or are phobic about seeing or feeling that they penetrate their skin. Our previous research focused on the impact of various needle characteristics on pain sensation during hypodermic injections and identified ways to reduce discomfort and injection-related phobia. We hypothesized that reducing the force required for needle penetration could minimize tissue trauma, and therefore, the pain experienced. That previous study investigated how factors such as cannula diameter, surface roughness, penetration depth, lubrication, and angle of the needle's bevel tip influence pain perception during injections, employing an artificial tissue model to gauge the effort needed for penetration. The findings indicated that needles with larger bevel angles required more penetration force, which correlated with increased pain perception among patients. In the presente study we further examined the wear and burr formation on repeatedly used needles using a profile projector and Scanning Electron Microscopy (SEM), which can hinder penetration and cause tissue damage. Additionally, we explored mechanical methods to prevent needles intended for subcutaneous injections from inadvertently penetrating muscle tissue. We developed a device to simplify the process of administering and self-administering injections, enhancing safety, comfort, and reducing the pain experienced by patients. This approach not only addresses the technical aspects of needle design but also considers the psychological impacts on patients, potentially improving therapeutic outcomes
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