Application Of Ultrasonic Atomization in Balloon Spraying

Drug-eluting balloons (DEBs) and functionally coated balloons are core devices in interventional vascular therapy. The uniformity of their coatings, the accuracy of drug loading, and their surface morphology directly determine clinical efficacy and safety. Ultrasonic atomization coating, with its advantages of low pressure and gentleness, uniform droplet distribution, controllable dosage, and high raw material utilization, has become the mainstream process for precision balloon coating and is widely used in the preparation of drug-eluting, anti-proliferative, and lubricating coatings for coronary, peripheral, and neurointerventional balloons. This article systematically elucidates the engineering value of ultrasonic atomization in balloon coating, covering its technical principles, core advantages, typical processes, application scenarios, and development trends.

Ultrasonic Atomization Spraying Principle

Energy Conversion: The ultrasonic generator converts electrical energy into high-frequency mechanical vibration (commonly 120–180 kHz), which is then transmitted to the atomization surface of the nozzle;

Liquid Atomization: The liquid material forms capillary waves on the atomization surface, which are broken into monodisperse micron-sized droplets (typically 10–20 μm);

Low-Pressure Deposition: With the aid of a weak airflow guide, the droplets are deposited uniformly and at low speed on the surface of the bulb, drying to form a film;

Precise Control: Closed-loop control of coating thickness and areal density is achieved through frequency, power, flow rate, rotation speed, and scanning speed.

Core Technological Advantages

Excellent Coating Uniformity: Narrow droplet size distribution ensures consistent coverage of curved and wrinkled areas, minimizing thickness error and preventing localized over- or under-drug administration.

Low Pressure and Gentle on Substrate: No high-pressure airflow impact prevents balloon deformation, wrinkling, or stretching, ensuring catheter size and structural precision.

Significantly Improved Drug Utilization: No severe scattering; drug utilization reaches over 85%, far exceeding traditional processes, significantly reducing the cost of expensive drugs.

Precise and Controllable Thickness: Supports nano- to micron-level coating; customizable single-layer/multi-layer gradient coatings meet sustained-release and controlled-release requirements.

Stable Coating Quality: Reduces pinholes, sagging, orange peel, and crystallization abnormalities, improving biocompatibility and clinical release consistency.

Wide Compatibility: Compatible with drugs such as paclitaxel, rapamycin, and sirolimus, as well as various medical polymers and hydrophilic coating systems.