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How Ultrasonic Coating Works

Ultrasonic coating is a precision deposition process that uses high-frequency vibrations to create a uniform, controlled film of liquid material on a surface. Unlike traditional spraying methods, ultrasonic coating does not rely on pressure or heat. Instead, it uses ultrasonic energy to atomize liquids into a fine mist of micron-sized droplets, resulting in superior control, minimal waste, and highly consistent coatings.

This technology is widely used in electronics, medical devices, textiles, energy applications, and advanced manufacturing, where accuracy and material efficiency are critical.

The Principle of Ultrasonic Atomization

At the heart of the process is the ultrasonic nozzle. The nozzle is driven by piezoelectric transducers that vibrate at ultrasonic frequencies (20–120 kHz). When liquid is delivered to the nozzle tip:

The vibration breaks the liquid into a thin film.
The film destabilizes into uniform micron-sized droplets.
These droplets form a soft, cone-shaped mist that deposits evenly onto the target surface.

Unlike pressure nozzles, ultrasonic atomization produces no high-velocity spray or turbulence, which makes it ideal for delicate substrates and applications requiring thin, pinhole-free coatings.

Key Components of an Ultrasonic Coating System

Ultrasonic Nozzle – Vibrates at high frequency to atomize liquid.
Liquid Delivery System – Precisely controls the flow of coating material.
Motion/Automation System – Moves the nozzle or substrate for complete coverage.
Power Supply & Generator – Provides the electrical energy to drive ultrasonic vibrations.
Process Controls – Allow adjustment of flow rate, spray pattern, and deposition area.

Advantages of Ultrasonic Coating

Uniform Thin Films – Consistent coating thicknesses as low as nanometers.
High Transfer Efficiency – Minimal overspray and wasted material.
Scalability – Works for both R&D and full production environments.
Versatility – Can process a wide range of materials, including polymers, biomaterials, nanoparticles, fluxes, and more.
Non-Clogging – Ultrasonic nozzles have no small orifices to block.
Environmentally Friendly – Reduced material usage and lower VOC emissions.

Common Applications

Medical Devices: Stents, catheters, diagnostic strips, and drug-eluting implants.
Electronics: Printed circuit boards (PCB), conformal coatings, fuel cells, and sensors.
Energy: Solar panels, batteries, and fuel cell membranes.
Textiles: Hydrophobic finishes and functional coatings.
Industrial: Glass, automotive components, and nanomaterials.

Why Choose Ultrasonic Coating?

Ultrasonic coating is not just a spray process — it’s a controlled deposition technology. By combining precision atomization with programmable automation, manufacturers achieve reproducible coatings that improve product performance, reduce costs, and enable innovations in next-generation technologies.

If you are considering ultrasonic coating for your application, our team at Ultrasonic Coating Systems can help you evaluate the best solution.