Precision Engineered and Made in the USA
Since 2010, MicroSpray has been a leader in advanced ultrasonic spray technology. Our high-performance nozzles are proudly designed and built in Central Pennsylvania. The company was founded with support from a Department of Energy (DOE) grant, with continued backing from Ben Franklin Technology Partners and PennTAP. That foundation of innovation drives every system we deliver today.
25 Years of Ultrasonic Micro-Spray Engineering
Mark Leiby
Founder & Lead Technologist
Founder and Lead Technologist Mark Leiby brings over 25 years of experience as an innovator in ultrasonic spray coating applications. A veteran engineering professional, Leiby played a pivotal role at Sono-Tek Corporation, where he served as Applications Engineer. During his tenure, he was instrumental in adapting ultrasonic nozzle systems for advanced precision coating applications including medical stents, chemical warfare sensors, and glass substrates.
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
Ultrasonic Liquid Atomization: Theory and Applications (1998)
Among these groundbreaking innovations are the ThinSonic™ systems — vacuum ultrasonic coating technologies originally licensed from Cornell University. These systems enabled direct liquid injection chemical vapor deposition (CVD), producing highly uniform thin films on three-dimensional medical and electronic substrates. The technology facilitated defect-free coatings on complex geometries including stents, MEMS devices, and OLED components.
Patents
Leiby is a named inventor on patents filed jointly with Sono-Tek and BAE (British Aerospace, now BAE Systems). These patents describe methods for coating three-dimensional substrates using ultrasonic atomization in a controlled vacuum environment — solving long-standing challenges in thin-film uniformity and deposition on intricate devices such as cardiac stents and drug-eluting implants.
Published Scientific Contributions
Leiby has authored peer-reviewed papers and industry articles that advanced the field’s understanding of ultrasonic atomization and thin-film fabrication using pulsed spray CVD methods.
- “Chemical Vapor Deposition by Pulsed Ultrasonic Direct Injection…” — MRS Proceedings (2001)
- “A Better Way to Produce Thin-Film Prototypes…” — Machine Design, Vol. 75:114 (2003)
Related Work
- Ultrasonic Atomization for Direct Liquid Injection CVD: Precursor Delivery Without the Volatility RequirementMicroSpray technical white paper, September 2026 (PDF)
Areas of Expertise
Our Partnerships
We collaborate with academia, R&D labs, and industry partners to develop both custom and established industrial applications. Whether you need an R&D system, a pilot line, or full-scale manufacturing capable of 50,000+ parts per hour, we can help.
Proudly Veteran Owned and Made in the USA
A veteran-owned business. Designed and manufactured in Central Pennsylvania.
- Veteran-owned small business
- CAGE 7FBP6
- Est. 2010
- Spring Mills, PA
Ready to work with us?
Our engineers work directly with you to select the right nozzle for your process — no guesswork, no over-engineering.