Balloon Catheter Coating Ultrasonic Spray Coating Equipment

The Balloon Catheter Coating Ultrasonic Spray Coating Equipment is a precision automated system designed specifically for large‑scale balloon coating production. Its key advantage is the ability to process 8 balloons simultaneously in a single run. Using ultrasonic spraying technology, it achieves high‑precision, high‑uniformity application of drug coatings, effectively meeting the stringent quality requirements for balloon catheter coatings in the medical field while greatly improving production efficiency. The equipment integrates multiple core technologies including ultrasonic atomization, multi‑station cooperative control, and precision motion control, and is widely used in the industrial manufacturing of various drug‑eluting balloons such as coronary balloons and peripheral balloons.

Centered on ultrasonic spraying as the core coating solution, the equipment offers significant advantages over traditional dip coating and two‑fluid spraying. The ultrasonic generator transmits high‑frequency vibrations to the nozzle, atomizing drug solutions or polymer coating materials into uniform micro‑ or even submicron droplets, which are then precisely deposited onto the balloon surface to form a dense coating. This atomization method effectively eliminates common defects in traditional processes such as pinholes, orange peel, and coating adhesion, ensuring coating thickness uniformity is controlled within a very narrow tolerance range and fully meeting the safety requirements for clinical application of balloon coatings. Meanwhile, the material utilization rate of ultrasonic spraying exceeds 85%, four times that of traditional two‑fluid spraying, greatly reducing the consumption of expensive drug raw materials and significantly lowering production costs.

The 8‑station synchronous processing system is the core customized module and key to improving productivity. The machine is equipped with 8 sets of independent yet synchronously cooperating fixtures and spraying units arranged in an array layout, ensuring that all 8 balloons experience consistent process conditions during spraying. Each fixture is fitted with a dedicated catheter holder compatible with various balloon catheter specifications, stably supporting catheters up to 2 meters in length. Excess catheters can be coiled and secured using a specialized storage structure to prevent movement during spraying that would compromise coating accuracy. Each fixture also integrates a precision inflation system that supplies compressed air at 2–3 bar to expand the balloon to its preset shape, providing a stable foundation for uniform coating.

The system is equipped with 8 high‑precision ultrasonic nozzles. Focused or micro‑fine nozzles can be selected according to balloon specifications, and the spray width can be precisely adjusted from 1 mm to 10 mm to accommodate balloons of different sizes. The nozzles are driven by a servo motion system that follows predefined trajectories with micron‑level positioning accuracy, ensuring uniform coating distribution both longitudinally and circumferentially on the balloon surface. In addition, the equipment uses a fully digital ultrasonic controller with a multi‑core high‑speed chip for multi‑closed‑loop ultrasonic control. Ultrasonic power is controlled with 0.01 W precision, allowing fine adjustment of atomization parameters according to coating material properties and achieving stable liquid flow output ranging from 0.001 ml/min to 2 ml/min.

For process stability and safety, the equipment features a complete protection system. A dual‑motor synchronous rotation system drives all 8 balloons to rotate stably at high speed, enabling full 360° coating without dead zones when combined with precise nozzle movement. An integrated submicron aerosol humidification system rapidly adjusts humidity inside the spray chamber to assist drug crystallization, enhance coating adhesion and durability, and prevent cracking or delamination. The entire machine uses corrosion‑resistant design compatible with common organic solvents including acetone, tetrahydrofuran, and chloroform, effectively extending service life. A dedicated exhaust interface allows direct connection to cleanroom ventilation systems to promptly remove solvent vapors generated during spraying and ensure a safe production environment.

In terms of operation and maintenance, the equipment features a full‑color touch screen and intuitive human‑machine interface for easy parameter setup, recipe storage, and production start‑up. A self‑cleaning system for the nozzles automatically performs cleaning after spraying to prevent clogging, reducing maintenance costs and downtime. Independent control of the 8 stations is supported, allowing flexible switching between synchronous production and single‑station debugging modes to improve operational flexibility. Optionally, an ultrasonic dispersion feeder can be integrated for online dispersion and stirring of nanoparticle suspensions, preventing agglomeration and sedimentation during spraying and ensuring uniform coating composition.

This customized equipment strictly adheres to relevant technical standards for balloon coatings and meets core quality requirements including clean coating appearance, accurate and controllable drug dosage, and compliant organic solvent residue levels. It is suitable for depositing various drug coatings such as paclitaxel and rapamycin derivatives. With its 8‑station synchronous processing capability, production efficiency is increased by more than 8 times compared to single‑station systems, effectively satisfying large‑scale manufacturing demands. It is a core piece of equipment for drug‑eluting balloon manufacturers pursuing high‑quality, high‑efficiency production.

About Cheersonic

Cheersonic is the leading developer and manufacturer of ultrasonic coating systems for applying precise, thin film coatings to protect, strengthen or smooth surfaces on parts and components for the microelectronics/electronics, alternative energy, medical and industrial markets, including specialized glass applications in construction and automotive.

Our coating solutions are environmentally-friendly, efficient and highly reliable, and enable dramatic reductions in overspray, savings in raw material, water and energy usage and provide improved process repeatability, transfer efficiency, high uniformity and reduced emissions.

Chinese Website: Cheersonic Provides Professional Coating Solutions