Orthopedic Implant Coating Systems
Ultrasonic nozzle systems are used to apply uniform thin film coatings onto orthopedic or dental implants to either promote or inhibit bioactivity with titanium or cobalt chromium devices, reducing HAIs and promoting osseointegration. Solutions sprayed include Hydroxyapatite, carbon nanotubes, antibiotic and anti-inflammatory solutions, and hydrophilic polymers containing Thermoplastic Polyurethanes.
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
- 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 orthopedic coatings. 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.
Several different types of orthopedic coatings can be applied with ultrasonic nozzle technology:
- Hydroxyapatite is a popular calcium orthophosphate coating for encouraging bone growth into the implant. Uniform coatings of hydroxyapatite onto porous substrates promote osseointergration, the firm anchoring of a surgical implants surrounded by bone growth.
- Biocompatible scaffold materials such as carbon nanotubes can also be sprayed with Sono-Tek ultrasonic nozzles to enhance bone growth.
- Antibiotic and anti-inflammatory coatings can be applied, reducing the threat of HAIs and implant failure due to infection.
- Hydrophylic polymer coatings, such as Thermoplastic Polyurethanes, are sprayed for added strength, lubricity and increased biocompatibility.
Nozzle tilt and rod attachment options for the
ExactaCoat & FlexiCoat systems are pictured above.