UltraSonic Spray Coater CPT-Ultra-19 by DATAMAKER

Overview

The DATAMAKER CPT-Ultra-19 UltraSonic Spray Coater is a precision-engineered benchtop deposition system based on high-frequency ultrasonic atomization (50 kHz). Unlike conventional pneumatic two-fluid spray systems, it generates fine, monodisperse droplets via piezoelectric transduction—where mechanical vibration at resonance frequency induces capillary wave instability at the liquid meniscus, resulting in controlled droplet ejection without compressed air assistance. This principle enables true low-velocity, low-shear delivery of functional liquids—including aqueous/organic solutions, sol-gels, nanoparticle dispersions, and conductive inks—onto temperature-sensitive or topographically complex substrates. Designed for R&D laboratories and pilot-scale manufacturing, the system delivers nanoscale thickness control, exceptional spatial repeatability, and minimal overspray—making it suitable for applications demanding strict material conservation, layer uniformity, and process traceability under GLP or ISO 17025-aligned workflows.

Key Features

• Integrated 3-axis programmable motion platform with 250 × 250 mm travel range and 200 mm vertical standoff adjustment for precise substrate positioning
• Single 50 kHz extended-tip ultrasonic nozzle delivering stable atomization across viscosities from 1 to 50 cP without gas assist
• G-code-based open architecture enabling custom trajectory definition, multi-pass layering, and patterned deposition (e.g., grid, spiral, raster)
• Real-time flow regulation with 1 µL/s resolution and closed-loop feedback for sub-micron thickness reproducibility
• Bilingual touchscreen HMI supporting English/Chinese operation; compatible with Windows, macOS, and Linux host environments
• Modular design with footprint under 0.6 m²—optimized for cleanroom integration and Class 1000+ environments
• Onboard SD card and USB interfaces support offline operation and audit-ready parameter logging

Sample Compatibility & Compliance

The CPT-Ultra-19 accommodates rigid and flexible substrates up to 280 × 230 mm, including silicon wafers, ITO/glass slides, polymer films, metal foils, and porous electrodes. It supports solvent-based, water-based, and viscous precursor formulations commonly used in thin-film photovoltaics (e.g., perovskite precursors), fuel cell MEA fabrication (Nafion® dispersions), biosensor immobilization (antibody/protein solutions), and microelectronics (photoresists, solder pastes, Ag/Cu nanowire inks). The system meets electromagnetic compatibility (EMC) requirements per IEC 61326-1 and conforms to general electrical safety standards (IEC 61010-1). While not FDA-certified as a medical device, its software architecture supports optional 21 CFR Part 11-compliant electronic signatures and audit trails when deployed with validated third-party LIMS or MES platforms.

Software & Data Management

Control is executed via DATAMAKER’s native cross-platform application, which imports G-code scripts editable in Notepad++ or similar plaintext editors. Each deposition job logs timestamped metadata—including flow rate, speed, Z-height, ambient temperature, and nozzle duty cycle—to local storage or network drives. Export formats include CSV and XML for post-processing in MATLAB®, Python (Pandas), or JMP®. The system does not require cloud connectivity; all processing occurs locally to ensure data sovereignty—a critical requirement for academic IP protection and industrial confidentiality. Optional API extensions enable integration with LabVIEW™ or Python-based automation frameworks for high-throughput screening protocols.

Applications

• Fuel cell R&D: Catalyst ink deposition onto gas diffusion layers (GDLs) and membrane electrode assemblies (MEAs) with <5% thickness variation across 10 cm² active areas
• Perovskite and organic photovoltaics: Sequential layer-by-layer coating of HTL/ETL/perovskite stacks with tunable thickness from 20 nm to 1 µm
• Biomedical microdevices: Conformal patterning of hydrogels, DNA probes, or enzyme layers on microfluidic channels and sensor arrays
• Semiconductor packaging: Selective flux application prior to reflow soldering, minimizing residue and bridging risk
• Optical coatings: Anti-reflective and hydrophobic SiO₂/TiO₂ sol-gel films on curved or textured glass surfaces
• Graphene oxide and MXene dispersion coating for flexible electronics and EMI shielding films

FAQ

What types of liquids are compatible with the CPT-Ultra-19?
Aqueous and organic solutions, colloidal suspensions (e.g., metal nanoparticles, quantum dots), sol-gels, polymer solutions (e.g., PVP, PVDF-HFP), and low-viscosity conductive inks (<50 cP) are routinely processed. Highly volatile or corrosive solvents require compatible wetted materials (e.g., PTFE, stainless steel 316); consult technical documentation for chemical resistance charts.
Can the system be integrated into automated production lines?
Yes—the G-code interface and digital I/O ports (TTL/RS-232) allow synchronization with PLCs, robotic arms, and conveyor systems. Custom OEM firmware variants support SECS/GEM protocol for semiconductor fab integration.
Is calibration traceable to national standards?
Flow calibration is performed using gravimetric methods traceable to NIST SRM 2810 (water) and certified microbalances (±0.01 mg). Certificate of Calibration is provided upon request with annual recalibration options.
How is process repeatability verified?
Users may execute built-in uniformity test routines that deposit identical patterns across nine predefined zones on a quartz slide, followed by profilometry or spectrophotometric thickness mapping—data exported for statistical analysis (Cp/Cpk reporting available).