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The paper presents a description of the development phases of the new third generation of “green” fuel injectors. The development objective for the new PICO-ECOlogical injector was to define a layout, which enables an optimal parameter configuration for both the mixture preparation (high flexibility to adapt different atomizer plate structures) and the manufacturing processes. It is demonstrated in which way the use of high-level numerical simulation and visualization techniques have become an integrated part of the development process. A detailed description is given of the new layout with respect to earlier versions and the advantageous new features obtained are discussed. Test results obtained by the new 3rd-generation injector layout are presented. The impact of the improved dynamic response capability is explained and experimental data at both engine test rig and vehicle FTP-cycle conditions are reported and discussed.