Stent coating systems for applying uniform anti-restenosis drug coatings onto cardiac, peripheral, biodegradable, and other implantable stents
Sono-Tek stent coating systems are considered the industry standard and are used by most of the largest drug-eluting stent (DES) manufacturers in the world. Our ultrasonic spray technology has been used for decades to apply drug-polymer coating solutions onto implantable stents, providing precise, repeatable results and superior coating quality. With more than 600 systems in operation globally, Sono-Tek’s MediCoat platforms are trusted by over 90% of the research and manufacturing institutions in the stent coating market.
Ultrasonic precision for complex geometries
Ultrasonic spray nozzles produce a soft, low-velocity atomized spray that penetrates complex stent geometries and ensures complete coverage of all strut surfaces without webbing or bridging. Droplet size and coating morphology can be precisely tuned by adjusting process parameters, allowing fine control over coating thickness and surface texture.
Compared to pressure or air-atomizing nozzles, ultrasonic spray provides far greater uniformity and efficiency. Coatings applied ultrasonically are significantly thinner and more consistent than dip coatings, reducing material use and eliminating webbing. Because ultrasonic nozzles are non-clogging, spray quality remains stable even during long production runs.
Advantages of ultrasonic spray for stent coatings
- Highly controllable and repeatable coating process
- Non-clogging ultrasonic nozzle design
- Flow control in the microliter-per-hour range
- Droplet sizes as small as 9 microns with narrow distributions
- Low-velocity spray adheres to stents without bounce-back or overspray
- Proven process for coating implantable stents and precision medical devices
- Durable coatings that resist flaking and peeling
- Over a decade of experience and hundreds of validated systems in production
- Qualification documentation available for installation, operation, and performance verification
MediCoat DES3000 / DES4000 systems
The MediCoat DES3000 and DES4000 are the most widely used ultrasonic stent coating systems in the world. They are the preferred choice for R&D, process development, and low-to-mid-volume production—and are also used by many high-volume manufacturers operating multiple systems in parallel to achieve desired throughput.
This modular, scalable approach allows customers to expand production capacity while maintaining the same validated coating process and performance from development through commercial manufacturing.
MediCoat DES high-volume platforms
For large-scale, automated manufacturing environments, Sono-Tek also offers the MediCoat DES High Volume platform family. These systems are designed for multi-stent coating and high-throughput operation, combining Sono-Tek’s proven ultrasonic technology with advanced automation and environmental control inside large, enclosed systems.
While details of these high-volume platforms are application-specific and not publicly disclosed, they are engineered to meet demanding production requirements for consistency, yield, and regulatory compliance.
MediCoat PSI system
The MediCoat PSI is a compact, benchtop glovebox coater designed for coating peripheral and specialty stents with drug-polymer formulations or other coating solutions. It provides a contained, turnkey environment and can be configured with custom stent holders or motion profiles to match specific coating needs. The PSI system is ideal for smaller-scale or specialized applications requiring precise, repeatable coatings in a fully enclosed, controlled environment.
Process validation and application expertise
Sono-Tek provides full validation criteria for stent coating processes using MediCoat systems, including installation, operation, performance, and maintenance qualification documentation. Our in-house coating laboratory allows customers to test and optimize coating parameters using their own stents and materials, supported by experienced engineers who have coated hundreds of different medical-grade polymers and drug-polymer formulations.
Sono-Tek’s MediCoat technology is relied upon by organizations such as the US FDA and leading global stent manufacturers to produce high-quality, repeatable drug-polymer coatings. With decades of experience and installations worldwide, Sono-Tek continues to define the standard for precision stent coating—from early R&D to full-scale production.
Contact Sono-Tek’s Medical Coating Team
Click here for a technical paper discussing drug-eluting coatings using ultrasonic spray technology: Application of Quality by Design (QbD) Approach to Ultrasonic Spray Coating of Drug-Eluting Stents.
Types of Stents Coated Using Ultrasonic Spray (Metal or Bioabsorbable Materials):
- Arterial
- Peripheral
- Sinus
- Bifurcated
- Bare Metal
- Biodegradable
- Stent Grafts