Ultrasonic Systems, Inc. (USI): Nozzle-Less Thin Film Coating Technology

Ultrasonic Systems, Inc. (USI)

is a global manufacturer of high-performance spray coating equipment based on its patented,
nozzle-less ultra-Thin Coating Application Technology (tCAT).
USI’s systems provide a precision coating alternative to both conventional air-atomizing
and traditional ultrasonic spray nozzle solutions.

Patented tCAT Coating Technology

Unlike conventional spray systems that rely on atomizing nozzles, USI’s tCAT technology
applies coatings without a nozzle. This approach enables highly uniform thin film deposition
while eliminating many of the common challenges associated with nozzle-based systems,
including clogging, inconsistent droplet size, and overspray.

• Nozzle-less coating application for improved reliability
• Highly uniform, repeatable thin film coatings
• Reduced maintenance and downtime
• Scalable from R&D to full production environments

Industries and Applications

USI’s coating systems are deployed across a wide range of advanced manufacturing markets
where precision, yield, and process stability are critical:

• Solar: Thin film coatings for photovoltaic and solar energy components
• Semiconductor: Precision coatings for wafers and microfabricated devices
• Fuel Cells: Uniform catalyst and functional layer deposition
• Medical: Coatings for medical devices requiring controlled film thickness
• Electronics Assembly: Functional and protective coatings for sensitive components

Global Presence and Industry Experience

With thousands of installations worldwide, Ultrasonic Systems has established
itself as a trusted technology provider across multiple industries. The company combines
proven coating hardware with deep application expertise, supporting customers from
early-stage process development through high-volume manufacturing.

USI’s team of technical specialists is known for delivering comprehensive
application development, system integration, and ongoing process support,
helping manufacturers optimize coating performance and production efficiency.

USI’s Role in the Ultrasonic & Thin Film Coating Landscape

While ultrasonic spray coating remains a core technology in thin film deposition,
USI’s nozzle-less tCAT approach represents an important alternative for applications
that demand extreme uniformity, high uptime, and reduced process variability.

Ultrasonic Systems, Inc. is part of the broader ecosystem of advanced coating technology
providers featured in our
Global Ultrasonic Coating Suppliers Directory,
which highlights manufacturers serving electronics, energy, medical, and industrial markets worldwide.