Ultrasonic spray coaters lay down catalyst inks, electrode slurries, and functional thin films with the droplet-size control and run-to-run uniformity that pressure-atomized airbrush systems cannot match. Instead of using high-velocity gas to shear a liquid, a piezoelectric nozzle vibrates at tens of kilohertz and breaks the feed into a low-velocity, narrowly distributed mist. The result is a soft, controllable plume that follows a programmed path over the substrate without overspray bouncing off the surface, which is what makes the technique the workhorse for fuel-cell catalyst-coated membranes (CCMs), gas diffusion electrodes, perovskite and silicon photovoltaic interlayers, sensor films, and lab-scale battery electrode coupons.
Compared with doctor-blade or slot-die coating, ultrasonic spray excels where the deposit must be thin (sub-micron to a few microns), where the substrate is fragile or non-flat (membranes, GDLs, frits, 3D parts), or where the ink is dilute and high-loss processes are unaffordable. Compared with conventional spray guns, the low-velocity plume preserves nanoparticle dispersion, avoids droplet impact damage on soft membranes, and gives far better edge definition.
This collection groups our programmable ultrasonic spray coaters by working footprint:
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Compact bench systems — small XY stages suited to coupon-scale R&D, single membranes, and catalyst-screening workflows
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Mid-format programmable systems — larger stages for full-size MEAs, multi-coupon batches, and method-development work that needs to translate to pilot scale
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Sealed / enclosed systems — interlocked enclosure with extraction for solvent-heavy or sensitive inks, including platinum-group catalyst layers and ionomer dispersions
All systems use programmable XY motion, controlled feed via syringe pump, adjustable nozzle height, and a heated vacuum chuck so films dry layer-by-layer without dewetting. They are compatible with Nafion and other PFSA ionomer dispersions, IrOx / Pt/C / Pd catalyst inks, carbon-supported electrocatalysts, perovskite precursor solutions, and standard battery slurries when diluted appropriately.
If you are coating membranes or GDLs for fuel cells and electrolyzers, look at the sealed and mid-format systems. For battery electrode R&D and slot-die method comparison, see also Battery Coaters and Coaters. For substrate prep before coating, see Laboratory Equipment.
