Precision Thin Film Medical Device Coatings

Ultrasonic nozzles systems are used to apply uniform thin film coatings onto diagnostic devices such as well plates for uniform cell growth during cell culture or onto sensors for many different functions. The systems can be oriented to spray in any direction, coating inner walls or 3 dimensional-shaped devices with ease. Using ultrasonic spray to coat complex devices that require the highest uniformity and repeatability is the most efficient way for it to be applied in a production setting. Ultrasonic spray coatings are highly controllable and offer very high transfer efficiency for very precise dispense of solutions or suspensions such as polymers, proteins and heparin mixtures.

Ultrasonic Coating Advantages:

• Major material cost savings versus dip coating methods
• Non-clogging nozzles are compatible with common polymer solutions
• Capable of spraying highly uniform coatings onto complex substrates
• Ultrasonic vibrations deagglomerate particles in suspension for more homogenous coatings
• Low velocity spray is easily controlled, minimizing overspray and excess material usage.
• Controllable spray allows for coating morphology to be adjusted for more porous or smooth characteristics

Sono-Tek offers a variety of ultrasonic nozzle configurations accompanied by fully programmable XYZ motion systems to deliver precision coating solutions. The ExactaCoat and Flexicoat are the coating systems of choice for the application of diagonostic devices. Due to the 360 degree rotation and nozzle tilt capability of the XYZ systems Sono-Tek is able to provide fully customizable coating solutions. Ultrasonic nozzles are capable of spray patterns ranging from 0.08 – 6″ wide (2-153mm), matched by an extensive array of flow rates, dependent upon nozzle selection and frequency.