Precision Ultrasonic Spray Nozzles for Research and Manufacturing
Zero-air atomization delivers flawless, micron-scale coatings with 95%+ transfer efficiency.
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From fuel cell membranes to drug-eluting stents — deep technical resources drawn from decades of ultrasonic atomization research.
Browse Research25+ Years Engineering Ultrasonic Spray Solutions
Founded by a former lead applications engineer at Sono-Tek Corporation.
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Nozzles, applications, industries, systems, and more — what you will find is that we are “out of the box” thinkers who work hard to provide engineered solutions to difficult problems at reasonable prices.
Nozzles
Six ultrasonic spray nozzles engineered for precision coating at every scale.
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Systems
Precision XYZ stages and coating platforms for repeatable deposition.
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Applications
Explore precision coating use cases across medical, energy, and electronics.
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Industries
Medical, energy, electronics, and research sectors we serve.
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Process Development
Process-level application notes and hands-on engineering support to dial in your coating process.
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Partnership/Research
Collaborate with our team on peer-reviewed research and feasibility studies. We will collaborate on SBIR and STTR projects.
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What are you coating?
Medical
Stent, catheter, syringe, and guidewire coatings
Energy
Fuel cells, solar cells, and catalyst layers
Mark Leiby is a sales engineer whose chief responsibility is in new applications. His ‘outside-of-the-box’ style of thinking has resulted in several significant new applications for the Company's technology.
Harvey L. Berger, PhD
Founder, Sono-Tek Corporation
Our founder brings 25+ years of hands-on ultrasonic spray engineering — from lab bench to production line.
Talk to an Expert| Frequency | Median Droplet Size | Maximum Flow Rate |
|---|---|---|
| 48 kHz | 40 µm | 2.4 mL/s |
| 60 kHz | 31 µm | 1.2 mL/s |
| 120 kHz | 12–15 µm | 0.4 mL/s |
No lower flow limit. Wetted materials: titanium, stainless steel, PTFE. Droplet size is independent of flow rate and pressure. Sizes are measured near the nozzle tip; droplets shrink in flight, so the size at your substrate depends on standoff distance and solvent.
Key Characteristics
- Zero air, zero fluid compression — purely acoustic atomization
- Low-velocity spray (~1 m/s) for material-efficient coating
- Self-cleaning, non-clogging titanium construction
- Best with low-viscosity liquids (below 50 cP, ideally below 20 cP)
- Vacuum and pressure compatible
- Driven by 20 W broadband generator, 25–120 kHz tracking range
Measured Droplet Data — 120 kHz
| D10 (arithmetic mean) | 14.3 µm |
| D32 (Sauter mean) | 39.3 µm |
| D43 (volume mean) | 59.4 µm |
| Mean droplet velocity | ≈0.8 m/s |
| Valid samples | 23,053 |
Phase Doppler particle analysis of water spray at 120 kHz; independent laboratory measurement.
Applications
Medical
- Drug-eluting cardiac stent coating
- Blood collection tube coating (heparin / EDTA)
- Implant and orthopedic scaffold coatings
- Medical device and diagnostic sensor coatings
- Precision drug delivery and microdosing
Industrial
- Thin-film solar cells and photovoltaics
- Semiconductor and IC wafer processing
- Fuel cell and battery electrode coating
- Carbon nanotube and graphene deposition
- Textiles, nonwovens, and flexible substrates
- Precision glass and optical coatings