KDF Hermetic Sealing Solutions - In Line Sputter Coating
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Hermetic sealing plays a pivotal role in the longevity and functionality of biocompatible implantable devices, such as pacemakers, cochlear implants, and biosensors.
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.
The importance of thin films in this context cannot be overstated. 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, such as those offered by KDF Technologies, 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. This ensures that implantable devices remain safe, effective, and reliable over their intended lifespan, highlighting the integral role of KDF Technologies in advancing medical device manufacturing.
Devices that benefit from hermetic sealing with biocompatible thin films, ensuring their reliability and safety for implantation, include:
Pacemakers:
These devices, which help 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 their sensitive internal electronics and maintain their performance over time.
Implantable Cardioverter-Defibrillators (ICDs):
Devices that monitor heart rhythms and can deliver electric shocks to correct irregular heartbeats, requiring 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 from the harsh environment inside the body.
Biosensors:
Implantable sensors that monitor various physiological parameters must have hermetic seals to ensure accurate readings over their operational life.
These examples underscore the critical importance of hermetic sealing and biocompatible thin films in the development and functionality of implantable medical devices, safeguarding their reliability and effectiveness for patient care.
KDF Magnetron Sputtering
Magnetron sputtering is well suited to providing these films. Sputtering systems from KDF Technologies are in use at leading medical device companies depositing films such Au, TiW, Ir, Ag, Zr, Ta, TaN, Ti, and TiN. With established technologies such as HIPIMS and Pulsed DC reactive sputtering we are in an ideal position to personalize a tool for your unique medical device application, backed by our team of dedicated applications, design and vacuum experts.
Key Capabilities
3-Dimensional and Large Parts
Parts up to 4” in thickness can be loaded into tall horizontal (900 series) systems.
Pallets can hold total loaded weights of up to 150 pounds (system specific).
Precious Metal Sputtering with Upsilon Inset™ Cathode
Specifically designed for high thermal conductivity, high value materials such as Gold (Au), Platinum (Pt), Palladium (Pd), Silver (Ag)
Water Pump:
Water pumps are high-performance pumps used in conjunction with the high vacuum pump (turbo or cryo) that increase water vapor pumping speeds to substantially improve system throughput and process stability.
Enhanced Rotating Planetary Pallet (ERPP) (900 series only):
The planetary rotating pallet ERPP™ (enhanced rotating planetary pallet) is a KDF design to achieve exceptionally high uniformity in the sub 1%, as well as tight repeatability.
(Ref: Vacuum Technology and Coating, December 2002).
HIPIMS:
HIPIMS (High Power Impulse Magnetron Sputtering) is a sputtering power supply and technique that can produce highly dense, smooth, and hard films with enhanced conformality or step-coverage for high aspect ratio applications.
Plasma Emission Monitoring (PEM):
Perfect your reactive processes with an advanced reactive feedback control system delivering improvements to deposition rates, coating properties and process stability. A PEM unit optically monitors the plasma emission from the cathode and can quickly adjust the reactive gas flow in order to maintain the process in high-rate metallic mode versus the low-rate poisoned mode.
Auto Rate Adjust (ARA):
Auto-rate-adjust will automatically adjust the scan speed or deposition power to account for a decrease in deposition rate from target wear, thereby maintaining a stable process thru the life of the target.
Water Cooling:
If heat during your process is a concern the chamber, internal shielding, and cathodes can all be water cooled.
Scan Velocity Control:
Allows the operator to create velocity profiles for the pallet as it passes through the deposition zone, enhancing film uniformities and rates.
IR Pallet Temperature Measurement:
Integrated pyrometer pallet/part temperature measurement. Instant feedback on temperature of your pallet and/or parts. Temperature readings can be integrated into recipes allowing for continued cooling, or heating, before proceeding with further recipe steps.
Have questions? Contact KDF about our in line sputtering tools
In line with your process
The most reliable in-line sputtering tools in the industry are developed and manufactured by KDF. All of KDF’s systems are engineered to meet versatility and high throughput demands across a number of markets at the industry’s lowest cost of ownership.
- Mainstream silicon
- Emerging materials
- Flat panel displays
- Optical communications
- Medical devices
Across all platforms, KDF’s in-line batch sputtering systems are easier to use and maintain than cluster tools. KDF’s solutions provide users with increased:
- Film uniformity
- Throughput run to run
- Process stability
- ROI
- Automation
- Tool uptime
- Reliability
- Environmental health and safety benefits
KDF meets the needs of its customers by quickly developing tailored solutions and building on its core competencies. KDF can specifically engineerits tools for increased throughput, ROI or time to market. All existing KDF equipment is supported with upgrades and retrofits. In addition, as theOEM for MRC batch systems, KDF sustains all MRC batch products offering complete parts and service support on a world wide basis.
943ix and 954ix
The 943ix and 954ix are two of KDF’s x Series™ products. They feature the latest KDF cathode designs, which have been lengthened to 17 inches, offering improved uniformity over the entire pallet. x Series™ cathodes are available in both Planar™, Inset™ and RF/DC LMM™ cathode form.