Ultrasonic Coating Systems: Precision, Scalability, and Control
Sono-Tek’s ultrasonic coating systems are complete, turn-key platforms for producing uniform, repeatable thin film coatings across advanced manufacturing industries — from medical devices and semiconductors to clean energy and glass.
Each ultrasonic coating machine integrates precision atomizing technology, customized liquid delivery, motion and temperature control, and process automation — all engineered to deliver unmatched coating quality and scalability.
From R&D to High-Volume Production
Sono-Tek systems are designed to scale seamlessly from laboratory process development to full manufacturing lines. The same core ultrasonic nozzle technology and process controls are used across all system sizes, ensuring consistent coating results as production increases.
R&D and Low-Volume Systems – Compact and flexible platforms enable process development, testing, and proof-of-concept coating work.
Pilot and Mid-Volume Systems – Modular conveyorized and batch configurations support multiple substrates and integrated process modules.
High-Volume Systems – Continuous inline and roll-to-roll architectures deliver scalable throughput for industrial and energy applications while maintaining coating uniformity and process repeatability.
Consistent Technology – Core ultrasonic frequency, liquid and gas flow control, and process software remain identical across platforms, guaranteeing product quality from development through production.
Integrated System Design
Sono-Tek’s thin film coating systems combine ultrasonic atomization with precise system-level control, where all subsystems — liquid delivery, nozzle selection, motion control, and environmental management — work together to determine final coating characteristics and thickness:
Liquid Delivery: Chemical-compatible pumps and reservoirs ensure consistent flow and suspension of slurries, solutions, and nanoparticle dispersions.
Ultrasonic Nozzle Engineering: Operating frequencies from 25–180 kHz define droplet size and atomization behavior, influencing coating morphology as part of the broader system design.
Spray Pattern Shaping: Multiple nozzle geometries and air-shaping options produce uniform films even on complex 3D substrates.
Parts Handling & Motion: Conveyorized, rotary, and multi-axis motion systems (XYZ, 6-axis, and beyond) provide precise control for small components, large substrates, and intricate geometries.
Thermal & Environmental Control: Heating, cooling, and curing modules manage high-temperature processes and reactive coatings.
Software & Automation: Advanced recipe management, data logging, and integration with factory controls for traceability and quality assurance.
Through this integration, Sono-Tek systems are capable of applying coating thicknesses ranging from sub-micron nano-layers (≈20–200 nm) to 30–100 microns, depending on the combination of process variables and application requirements.
Application Engineering and Forward-Deployed Expertise
Sono-Tek’s growth is driven by the continued expansion of our applications engineering capabilities and our global laboratory network. Our engineering team works directly with customers to:
- Define the appropriate liquid chemistries and coating parameters
- Customize substrate handling and integration with upstream and downstream processes
- Ensure complete, optimized system integration within each customer’s production environment
To further accelerate our customers’ success, Sono-Tek has introduced Forward Deployed Engineers — specialized experts embedded directly into key customer projects. These engineers often work on-site at customer facilities, guiding process implementation and helping transition from R&D to full-scale manufacturing. This close collaboration ensures faster optimization, smoother integration, and higher long-term performance of every Sono-Tek ultrasonic coating system.
Ultrasonic Coating Machines: Engineered for Demanding Applications
Sono-Tek coating systems serve a broad spectrum of industries:
Electronics & Semiconductors: Photoresist, CNT, OLED, and MEMS coatings
Alternative Energy: Fuel cell, battery electrode, and solar panel coatings
Medical & Biomedical: Drug-eluting stents, catheters, drug-eluting balloons, diagnostic devices, and hydrophilic coatings
Industrial & Glass: Protective, hydrophobic, and anti-reflection coatings on large panels
Each system can be configured for high-temperature environments, inert atmospheres, or specialized materials such as nanoparticle suspensions, slurries, and reactive chemistries.
Advantages of Sono-Tek Ultrasonic Coating Systems
- Highly uniform, controllable thin film coatings from 20 nm to 100 µm
- Non-clogging ultrasonic nozzles with long life
- Dramatic reduction in overspray and material waste (up to 80% savings)
- Independent control of flow rate, droplet size, and deposition rate
- Environmentally friendly low-energy atomization process
- Scalable from single-nozzle R&D units to multi-nozzle production platforms
Global Engineering Support
Sono-Tek’s multidisciplinary team — including mechanical, electrical, and software engineers — provides full system customization from design through installation, with worldwide service and support.
Explore Scalable Thin Film Coating Solutions
For nearly 50 years, Sono-Tek has led the world in ultrasonic coating system innovation, helping manufacturers transition from concept to high-volume production with precision, efficiency, and sustainability.
Contact Sono-Tek to discuss your process and learn how our ultrasonic thin film coating systems can scale with your manufacturing needs.