Sono-Tek is recognized across the renewable energy industry for its precision ultrasonic coating technology, which improves efficiency, lifespan, and cost-effectiveness in clean-energy devices. Unlike high-temperature thermal spray coating methods that apply thick metallic or ceramic layers, Sono-Tek’s ultrasonic coating technology enables low-energy, precision deposition of thin functional films for renewable energy applications such as hydrogen electrolyzers, fuel cells, solar panels, advanced batteries, and transparent conductive oxides (TCOs).
With more than four decades of experience in thin-film deposition, Sono-Tek’s scalable coating platforms, incorporating our proprietary ultrasonic nozzles, enable breakthroughs in the production of durable catalyst materials used in green hydrogen generation, functional thin-film solar energy coatings, and next-generation PEM and SOFC fuel cell coating technologies. Our coating systems help manufacturers and researchers achieve consistent, repeatable results while supporting global advancements in renewable energy.
Hydrogen Electrolyzers
Sono-Tek’s precision coating systems apply catalyst and ionomer layers on membranes and porous transport layers (PTLs) with exceptional uniformity, improving electrolyzer durability and overall energy efficiency. This cost-effective approach supports the rapid growth of green hydrogen production by reducing expensive material waste and extending system lifespan.
Fuel Cells
For fuel cell manufacturing, Sono-Tek’s ultrasonic nozzles and coating platforms deliver thin, highly controlled catalyst layers, with controllable porosity, boosting performance and reliability. Our coating technology enhances conductivity and power density, providing a proven solution for scalable, durable Proton Exchange Membrane (PEM) and Solid Oxide Fuel Cell manufacturing.
Thin-Film Solar Cells
Sono-Tek’s ultrasonic spray systems are trusted worldwide in photovoltaic and thin-film solar panel manufacturing, including next-generation perovskite solar technologies, for the precise application of functional and protective coatings. These uniform thin films enhance long-term durability, helping drive advancements in solar energy efficiency, cost-effective production, and sustainable renewable energy solutions..
Advanced Battery Coatings
From electrode protection to polyimide insulation, Sono-Tek enables manufacturers to create thinner, lighter, and more durable battery layers. Our ultrasonic coating technology improves adhesion and uniformity, extending battery lifespan and reliability in demanding energy-storage applications.
Spray Pyrolysis / TCO Processes
Sono-Tek’s spray process produces highly uniform oxide precursor layers for transparent conductive oxide (TCO) and other functional coatings used in photovoltaic and high-temperature applications. These systems are primarily utilized in R&D and pilot-line environments, where precise coating technology supports material development and process optimization.
Because many TCO precursor chemistries are highly corrosive, Sono-Tek offers customized system configurations built with corrosion-resistant materials, including specially engineered ultrasonic nozzles designed to perform reliably in aggressive chemical environments. This option provides long-term durability and consistent coating precision while minimizing maintenance requirements. Our flexible platform design enables researchers to advance next-generation renewable energy materials through dependable deposition under demanding thermal and chemical conditions.