RESEARCH APPLICATION
Aerosol Generation
Ultrasonic atomizers for laboratory aerosol generation — a fine, stable, low-velocity mist from solutions and suspensions for reactor feeds, CVD precursor delivery, inhalation research, and instrument calibration.
The Challenge
Research rigs that consume an aerosol — flame and furnace reactors, spray CVD, exposure chambers, particle instrument calibration — need a droplet source that is stable for hours, tightly distributed in size, and independent of the carrier gas flow. Compressed-air atomizers couple droplet generation to air pressure, pneumatic nebulizers pulse and drift, and both produce broad droplet spectra that smear downstream particle size. Suspensions settle and clog fine orifices mid-experiment.
Our Solution
MicroSpray ultrasonic atomizer nozzles generate droplets by tip vibration alone, so the aerosol output is decoupled from your carrier gas — you set gas flow and liquid feed independently. Droplet size is fixed by the operating frequency (12–15 µm at 120 kHz, 30–35 µm at 60 kHz, 38–45 µm at 48 kHz) and holds constant across the flow range. The self-cleaning vibrating tip keeps suspensions and salt solutions flowing for long unattended runs, and the compact nozzle body mounts into custom chambers and reactor ports with standard adapters.
Why Ultrasonic Spray?
- ✓Narrow, frequency-defined droplet size distribution
- ✓Aerosol output independent of carrier gas — set each parameter separately
- ✓Stable output over hours-long experiments, no pulsing or drift
- ✓Ultra-low flow rates from below 0.5 mL/min for precious solutions
- ✓Runs salt solutions, nanoparticle suspensions, and solvent mixes without clogging
- ✓Low-velocity mist won't blast delicate targets or disturb chamber flow fields
- ✓Compact bodies integrate into reactors, ducts, and chambers via standard adapters
- ✓Standalone nozzle + generator components for custom lab setups
Recommended Equipment
Zero Air Nozzle
Pure ultrasonic atomization with no compressed air — the cleanest decoupled aerosol source
View details →Vortex Nozzle
Adjustable air shaping entrains and directs the aerosol where the rig needs it
View details →ThermalSpray™ High-Temperature Ultrasonic Nozzle
Feeds aerosol into heated furnaces and reactors at up to 300°C
View details →Liquid Delivery (Dosing Pump)
Pulse-free liquid feed sets aerosol output independent of carrier gas
View details →Common Questions from Research Groups
What droplet size does an ultrasonic atomizer produce?
Droplet size is determined by the nozzle's operating frequency: roughly 38–45 µm median at 48 kHz, 30–35 µm at 60 kHz, and 12–15 µm at 120 kHz. Unlike pressure or two-fluid atomizers, the distribution is narrow and stays essentially constant across the flow range.
Can I run suspensions or salt-laden solutions without clogging?
Yes. The liquid path is a large open passage rather than a fine orifice, and the tip's ultrasonic vibration continuously redisperses particles and prevents buildup. Nanoparticle suspensions, dissolved metal salts, and solvent mixtures are routine.
Is the aerosol output tied to my carrier gas flow?
No — that's the key difference from pneumatic nebulizers. Atomization happens by tip vibration, so the liquid feed rate sets aerosol mass output and your carrier gas is free to be whatever the experiment requires, including none at all with the Zero Air Nozzle.
Can the nozzle be integrated into a custom reactor or chamber?
Yes. The nozzle bodies are compact and mount through standard NPT thread, flange (including vacuum KF/CF/ISO), and flex-mount adapters. Most research customers buy just the nozzle and generator and integrate them into their own rigs — no complete system purchase is required.
What support do you provide to labs outside the USA?
MicroSpray products are made in the USA and shipped worldwide. Engineers handle technical support directly by email and video call, and we regularly work with university groups in Europe and Asia. Contact us for lead times and shipping to your country.
Need a stable aerosol source for your experiment? Tell us your liquid and flow rate.
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