COATING PROCESS
Spool-to-spool continuous precoating technology that makes a difference
At Merit Medical Coatings, we understand that smooth medical grade coatings with consistent characteristics and advanced capabilities, contribute directly to more successful clinical outcomes. We’ve been working for several decades to develop and refine a world renowned spool-to-spool continuous precoating process that enables us to deliver (guide)wire, and coated mandrels that offer increased precision and superior performance.
With Merit’s proprietary precoating process, long, continuous lengths of uncoated wires are taken from one spool, fed through an immersive coating and curing process, and then wound back onto a second spool. This method provides a number of important advantages over other coating methods:
Continuous means consistent
Applying coatings to long, continuous lengths of wires before they are cut, coiled, or finished makes it possible to achieve higher levels of consistency and precision. With this process, all of the individual components cut and finished from the same spool of coated wire will share exactly the same characteristics and avoid irregularities that can occur when components are sprayed or dipped after they are cut. This continuous process also eliminates any potential cracking that can occur when guidewires are coated after they are coiled.
Thin layers for maximum flexibility
The Merit Medical Coatings continuous coating process is applied in thin precise layers. This typically includes a primer layer, followed by different combinations of smooth, hard, tough, or flexible topcoats. This layered approach makes it possible to create coated wires with a wide range of characteristics and capabilities to meet a wide range of medical requirements.
Low impact curing
Other coating processes can affect the properties and characteristics of certain base materials. Merit uses a proprietary curing process that has a minimal impact on the base materials, so you can take full advantage of their original strength and flexibility.
Unlimited coating options
The Merit Medical Coatings coating process makes it possible to apply combinations of coatings to a wide variety of materials and diameters. This includes the ability to coat wires made from stainless steel, nitinol, tungsten, and other materials upon request.
Superior finishing
After your (guide)wire or mandrel components are coated to your exact specifications, Merit Medical Coatings can complete the process with some of the industry’s most advanced finishing options, such as cutting, ends rounding and grinding. Thanks to our trusted subcontractors we can offer you cleaner, more precise, and more consistent custom cuts and finishes on both coated and uncoated surfaces.
R&D coating technology that pushes the boundaries
Innovation never stops at Merit Medical Coatings. Our commitment to progress drives us to continuously challenge the current process and redefine what’s possible in coating technology. We’re proud to introduce a breakthrough solution in 2026 that takes precision and performance to the next level.
Our latest proprietary coating technology opens doors to capabilities that were previously out of reach. This advanced system allows us to coat products in cut-to-length pieces, enabling unique features such as coated- rounded ends, tapered lengths, and even complex geometries like coils. By expanding these possibilities, we deliver coatings that meet the most demanding requirements with unmatched accuracy. With this state-of-the-art solution, we’re setting new standards for flexibility and customization, ensuring that every product performs exactly as intended in critical applications.
