Hermetic Sealing &
Biocompatible Thin Films
Hermetic sealing plays a pivotal role in the longevity and functionality of implantable medical devices. KDF's inline sputtering systems deliver the precision, uniformity, and biocompatibility required for pacemakers, cochlear implants, biosensors, and more.
The Role of Thin Films in Hermetic Sealing
These devices require seals that not only prevent the ingress of bodily fluids, gases, and particles but also ensure compatibility with human tissue over extended periods. An effective hermetic seal is crucial for protecting the device's sensitive internal components from corrosion and degradation, which could otherwise compromise its performance and reliability when implanted in the human body.
Advanced thin film technologies enable the creation of barriers that are impermeable to contaminants while being biocompatible and non-reactive with bodily tissues. These films, often deposited using Physical Vapor Deposition (PVD) techniques, can include materials like parylene, silicon nitride, or alumina — known for their excellent barrier properties and compatibility with human tissue.
KDF Technologies' expertise in sputtering and thin film deposition is critical for manufacturing implantable medical devices with hermetic seals. The precision and control offered by KDF's sputtering tools allow for the deposition of uniform, defect-free layers that are essential for achieving the desired hermeticity and biocompatibility.
Sputtering systems from KDF Technologies are in use at leading medical device companies depositing films such as Au, TiW, Ir, Ag, Zr, Ta, TaN, Ti, and TiN. With established technologies such as HIPIMS and Pulsed DC reactive sputtering, KDF is in an ideal position to personalize a tool for your unique medical device application.
Implantable Devices That Benefit from Hermetic Sealing
Biocompatible thin films ensure reliability and safety for implantation across a wide range of active and passive medical devices.
Pacemakers
Devices that regulate the heart's rhythm rely on hermetic seals to protect their electronic components from bodily fluids, ensuring long-term functionality.
Cochlear Implants
Implants that restore hearing for individuals with profound hearing loss must be completely sealed against bodily fluids to protect sensitive internal electronics.
Implantable Cardioverter-Defibrillators (ICDs)
Devices that monitor heart rhythms and deliver electric shocks to correct irregular heartbeats require robust hermetic seals to function reliably within the body.
Neurostimulators
Used for treating neurological disorders like Parkinson's disease and chronic pain, these devices need effective hermetic sealing to protect their electronic circuits.
Biosensors
Implantable sensors that monitor physiological parameters must have hermetic seals to ensure accurate readings over their full operational life.
Feedthroughs & Interconnects
Electrical feedthroughs require hermetic thin film coatings to seal lead/housing interfaces against body fluid ingress while maintaining electrical conductivity.
System Features for Medical Device Applications
KDF's inline sputtering platforms include a full range of process and hardware options purpose-built for the demands of hermetic sealing and biocompatible thin film deposition.
3-Dimensional & Large Parts
Parts up to 4" in thickness can be loaded into tall horizontal 900 series systems. Pallets hold total loaded weights of up to 150 lbs (system specific).
Upsilon Inset™ Cathode — Precious Metal Sputtering
Specifically designed for high thermal conductivity, high-value materials such as Gold (Au), Platinum (Pt), Palladium (Pd), and Silver (Ag).
HIPIMS
High Power Impulse Magnetron Sputtering produces highly dense, smooth, and hard films with enhanced conformality for high aspect ratio applications.
Enhanced Rotating Planetary Pallet (ERPP)
KDF's proprietary ERPP™ achieves exceptionally high uniformity in the sub ±1% range, with tight run-to-run repeatability. Available on 900 series systems.
Plasma Emission Monitoring (PEM)
Advanced reactive feedback control for improvements to deposition rates, coating properties, and process stability. Maintains the process in high-rate metallic mode.
Auto Rate Adjust (ARA)
Automatically adjusts scan speed or deposition power to account for target wear, maintaining a stable and repeatable process throughout the target's life.
Scan Velocity Control
Allows the operator to create custom velocity profiles for the pallet as it passes through the deposition zone, enhancing film uniformity and deposition rates.
IR Pallet Temperature Measurement
Integrated pyrometer provides instant feedback on pallet and part temperature, with readings integrated into recipes for controlled heating and cooling steps.
Water Pump & Cooling
High-performance water pumps increase water vapor pumping speeds to substantially improve system throughput and process stability. Full water cooling available on chamber, shielding, and cathodes.
943ix & 954ix — x Series™
The 943ix and 954ix are two of KDF's flagship x Series™ products. They feature the latest KDF cathode designs, lengthened to 17 inches, offering improved uniformity over the entire pallet.
x Series™ cathodes are available in Planar™, Inset™, and RF/DC LMM™ cathode form — giving process engineers the flexibility to dial in the exact deposition characteristics required for hermetic sealing applications.
- 17" cathode length for improved pallet-wide uniformity
- Planar™, Inset™, and LMM™ cathode options
- Compatible with ERPP, HIPIMS, PEM, and ARA options
- Proven at leading implantable device manufacturers
- Full MRC batch system lineage and parts compatibility
Ready to Discuss Your Hermetic Sealing Application?
KDF's applications, design, and vacuum engineering teams are ready to help you configure the right sputtering solution for your implantable device manufacturing process.
