Ultrasonic Catheter Coating Systems
Sono-Tek ultrasonic catheter coating systems are engineered for precise, repeatable deposition of lubricious, hydrophilic, and functional coatings on catheters, guidewires, and medical tubing. These fully enclosed medical device coating systems enable uniform film thickness, efficient material use, and consistent coating quality across production runs. Batch coating capability supports up to 5 catheters per coating cycle.
Technical Overview
The MediCoat CC1000 utilizes a precision ultrasonic nozzle that atomizes coating solutions into micron-sized droplets. The resulting low-velocity spray produces thin, highly uniform coatings with excellent control over thickness and surface coverage. The system’s programmable motion profile allows linear translation up to 1,000 mm and rotational speeds up to 400 RPM, supporting long substrates and complex geometries.
Key System Parameters
- Nozzle type: AccuMist ultrasonic nozzle
- Spray pattern width: 2–10 mm
- Linear travel: 1,000 mm (single-axis)
- Rotational speed: Up to 400 RPM
- Liquid use reduction: Up to 80% compared with conventional air spray methods
Advantages of Ultrasonic Spray for Catheter Coating
1. Precision Film Thickness and Coverage
Ultrasonic atomization enables droplet sizes in the 20–60 µm range, producing uniform, defect-free coatings. This level of control is critical for achieving consistent lubricity and surface performance in catheter assemblies. Uniform coverage is achieved with drastic reduction in spray material compared to other coating methods.
2. Material Efficiency
The ultrasonic nozzle generates a controllable, low-velocity spray plume that minimizes overspray and waste. In most cases, fluid consumption is reduced by 70–80% relative to dip coating or pneumatic spray processes. The drastic reduction in material consumption allows for fast drying times.
3. Selective-Area and Multi-Layer Coating
The narrow spray pattern allows targeted application to specific regions. The system supports sequential deposition of multiple layers — for example, base primer, lubricious topcoat, and protective overlayer — with rapid drying between passes.
4. Process Control and Repeatability
Motion control parameters (translation speed, rotation rate, and spray flow) are fully programmable for process optimization. The CC1000 delivers consistent film characteristics from R&D through production, ensuring repeatable coating results over extended use.
5. Scalability for Production Environments
The MediCoat CC1000 can be configured for standalone laboratory operation or integrated into automated catheter coating lines. Its modular design supports custom fixture options, environmental controls, and data logging for process validation.
Applications
- Hydrophilic and lubricious coatings for catheters and guidewires
- Biocompatible and drug-eluting coatings
- Selective functional coatings on tubing and small-diameter shafts
- Multi-layer coating development and process scale-up
Summary
The MediCoat CC1000 ultrasonic catheter coating system provides a controlled, efficient, and scalable platform for applying thin, uniform films to medical devices. By combining precision ultrasonic spray technology with robust motion control, it enables reproducible coating performance for critical medical applications where surface quality and uniformity are essential.
Visit https://www.sono-tek.com/ultrasonic-coating/ultrasonic-spray-benefits/ to learn more about how ultrasonic spray is an effective method for applying thin film coatings onto catheters.