Diagnostic Device Coating System for Precision Reagent and Microfluidic Coatings
Sono-Tek ultrasonic coating systems deliver highly uniform, repeatable thin films for a wide range of diagnostic and medical device applications. From microfluidic chips to reagent-coated strips and point-of-care consumables, our coating solutions enable precise low-volume application of biological reagents, polymers, and functional layers while minimizing waste and protecting sensitive substrates.
Compared to a conventional spray gun, ultrasonic atomization provides a gentler, more controlled spray ideal for achieving consistent coating thickness and highly uniform deposition of advanced coating materials. These coating technologies support high-quality thin films for diagnostics, drug delivery features, and engineered medical device coating applications throughout the medical device industry and modern medical device manufacturing.
Ultrasonic Precision for Diagnostic and Reagent Coating
Ultrasonic nozzles create a soft, low-velocity spray that deposits uniform reagent films without disturbing microstructures or affecting biocompatibility. This gentle deposition approach is ideal for microfluidic patterns, well plates, strip zones, biosensor features, and polymer-coated diagnostic components where uniformity, durability, and stability are essential.
Coating parameters can be tuned for:
- Ultra-thin reagent layers and functional thin films
- Narrow or wide spray patterns
- Controlled line widths down to sub-millimeter scale
- Consistent deposition on plastics, glass, metal, or membrane substrates
- High-efficiency use of costly coating liquids and specialized coating materials
- Hydrophilic coatings, lubricity layers, and other functional surface treatments
- Fine control of coating thickness for medical device performance requirements
Spray widths range from under 1 mm to over 100 mm depending on nozzle and air-shaping configuration.
Applications for Diagnostic Device Coating
Sono-Tek coating equipment supports precision coating processes for:
- Microfluidic and microarray devices
- Point-of-care diagnostic cartridges
- Blood collection and analysis devices
- Immunoassay strips and sensor pads
- Enzyme, reagent, and polymer coating materials
- Cell culture and assay surfaces
- Diagnostic membranes, porous substrates, and drug-delivery interfaces
These devices benefit from uniform, repeatable coatings that improve test sensitivity, wicking behavior, surface flow dynamics, and overall performance.
Benefits of Sono-Tek Diagnostic Device Coating Systems
- Highly uniform thin films with excellent repeatability
- Up to 80% reduction in reagent and coating liquid consumption
- Ultra-low flow control for costly biological and antimicrobial materials
- Non-clogging ultrasonic nozzles for consistent operation
- Precise microfeature coating with minimal masking requirements
- Enclosed spray environment suitable for clean processing
- Scalable coating system options from R&D to high-volume automation
- Low-energy atomization that preserves biological activity and biocompatibility
- Suitable for hydrophilic coatings, lubricity layers, polymer coatings, and functional surface treatments
Proven in High-Throughput and Multiplex Diagnostic Platforms
Sono-Tek ultrasonic coating technologies are widely used by global OEMs developing advanced in-vitro diagnostic instruments. Our systems support reagent and functional coatings for multiplex molecular assays, cartridge-based sample-to-answer platforms, and other next-generation diagnostic systems requiring reliable, high-quality thin film deposition.
This experience positions Sono-Tek as a trusted partner for manufacturers producing scalable, high-throughput diagnostic instruments where consistent coating performance is critical to sensitivity, reproducibility, and system reliability.
System Options for Diagnostic and Microfluidic Coating
ExactaCoat – R&D and Small-Scale Production
A fully enclosed, programmable benchtop coater ideal for early-stage development of diagnostic and medical device coating applications. Features include programmable XYZ motion, automation options, optional heated and vacuum plates, vision alignment, MicroFlow pumps for ultra-low volumes, and compatibility with multiple ultrasonic nozzle types.
FlexiCoat – R&D to High-Volume Production
A servo-driven coating system with a large motion range and high-precision positioning. Supports microfluidic coatings, reagent deposition, thin films, hydrophilic coatings, polymer coatings, and both pilot-scale and high-volume production environments for diagnostic and implant-related manufacturing.
Ultrasonic Nozzle Options
- PicoMist – sub-1 mm lines and ultra-fine spray patterns
- AccuMist – narrow, shaped microfeature coatings
- Vortex – circular wide-area spray patterns
- Impact – fan-shaped patterns for broader coverage
These nozzles offer flexibility for coating diagnostic geometries, sensor pads, guidewires, catheters, and a wide range of medical device components.
Process Support for Diagnostic Device Manufacturers
Sono-Tek’s Applications Engineering team provides coating process guidance, coating liquid selection assistance, system configuration support, and integration help for medical device manufacturing workflows. This includes optimization for thin films, antimicrobial materials, hydrophilic coatings, lubricity layers, polymer films, drug-delivery interfaces, and other specialized coating materials.
Our experience helps customers achieve consistent, high-quality coating application results as they scale from R&D to automated production.
Contact Sono-Tek for Diagnostic Device Coating Solutions – discuss your project or request guidance on selecting the optimal Diagnostic Device Coating System, coating equipment, microfluidic coater, or reagent coating machine for your application.
