At 2 mg/mL a 0.25 mg draw is 12.5 units on a U-100 barrel and a 2.4 mg draw is 120. Those two numbers decide it, because the concentration is only sensible relative to the smallest and largest volumes you will actually measure with it. 120 units will not fit a 1 mL U-100 barrel in one draw, which makes the large end the constraint rather than the small one. The other consideration is time: a vial you will finish in a fortnight can be concentrated, and a vial you will draw from for months should be split at reconstitution instead.
Answer first: diluent volume sets concentration and therefore resolution on the syringe barrel, and resolution is free at reconstitution and impossible to recover afterwards.
Worked example. A 10 mg vial reconstituted with 2 mL gives 5 mg/mL. A 0.5 mg dose is 0.5 ÷ 5 = 0.1 mL, which on a U-100 syringe is 10 units. Reconstitute the same vial with 1 mL and the concentration doubles to 10 mg/mL, the same dose becomes 0.05 mL, and you are now reading 5 units instead of 10 — the same dose at half the resolution.
On the detail: vial headspace is the hard constraint. A nominal 2 mL vial typically holds a little over 2 mL to the shoulder; adding 3 mL is not an option and attempting it wastes the lot.
Published content assay results across the independent testing services show nominal and measured content differing by one to ten per cent, which makes content the dominant term in dose error.
The caveat is that this arithmetic assumes the vial contains what the label says, and without a content assay it is precise about an unknown quantity.
Choose the volume that puts your largest intended dose between 10 and 30 units. Everything else follows.
edited 23 Jul 2026 by ines_brandt — clarified the distinction between purity and content