Medical Coating Solutions for Advanced Device Performance

Engineered metal coatings that enhance visibility, orientation, conductivity, durability, and reliability in minimally invasive and implantable medical devices

What Are Medical Coating Solutions?

Medical coating solutions involve applying engineered metal layers to device components to enhance performance without altering core design or geometry.

In modern medical devices, especially catheter-based and minimally invasive systems, coatings play a critical role in enabling functionality such as electrical conductivity, corrosion resistance, and device visibility and/or orientation during procedures.

ProPlate specializes in selectively applying precious metals such as gold, platinum, and palladium to targeted areas, allowing manufacturers to meet performance requirements while maintaining tight tolerances and low-profile designs.

Why Coatings Matter in Medical Devices

As devices become smaller and more complex, coatings are essential to achieving required performance without adding bulk or complexity.

Medical coatings enable:

  • Electrical conductivity for sensing, stimulation, and signal transmission
  • Corrosion resistance in physiological environments
  • Improved durability and wear resistance
  • Device visibility and orientation under fluoroscopy
  • Functional surfaces without increasing device size
  • Integration of multiple capabilities into a single component

Coatings allow engineers to solve performance challenges while maintaining manufacturability and scalability.

Precision Targeted Metal
View Case Studies & White Papers

Key Coating Capabilities

Radiopaque Coatings
(Vizi-Band®)

Enhances device visibility and orientation under fluoroscopy through selective gold and platinum application without increasing profile or adding components.

Metal Deposition on Polymers (Meta-Poly®)

Applies conductive metal layers to flexible substrates, enabling electrodes and signal pathways while maintaining material flexibility.

Corrosion-Resistant Coatings

Protects components from degradation in harsh physiological environments, extending device life and reliability.

Electrical Contact Surfaces

Improves signal transmission and connection reliability in electrodes, connectors, and sensing components.

Selective Precious Metal Plating

Applies metal only where needed, reducing material usage while maintaining performance.

Thin, Conformal Coatings

Supports miniaturization by delivering uniform coverage without impacting component geometry.

Have a coating challenge in your device design?

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Medical Device Segments We Support

ProPlate supports a wide range of medical device segments. Each area presents unique design and manufacturing challenges that influence plating requirements.

Cardiac & Electrophysiology

Cardiac Rhythm Management (CRM)

Implantable devices used for monitoring and regulating heart rhythm

Electrophysiology (EP)

Catheter-based mapping and ablation systems

Pulsed Field Ablation (PFA)

Next-generation ablation technology using pulsed energy

Structural & Interventional

Structural Heart

Transcatheter valve repair and replacement devices

Interventional Cardiology

Devices used in minimally invasive coronary procedures

Left Atrial Appendage Closure (LAA)

Implants designed to reduce stroke risk

Intravascular Lithotripsy (IVL)

Devices used to treat calcified vascular lesions

Neurovascular

Neurovascular

Devices used to treat conditions within the brain’s vascular system

Explore devices used in aneurysm treatment, stroke intervention, and embolization procedures.

Explore Neurovascular Applications→

Peripheral & Renal

Peripheral Vascular

Devices used in vessels outside of the heart and brain

Peripheral Vascular Assist Devices (PVAD)

Support devices for circulatory function

Renal Denervation (RDN)

Catheter-based treatment for hypertension

Additional Applications

Robotic-Assisted Surgery

Devices enabling precision-controlled minimally invasive procedures

 

Electrosurgery

Energy-based devices used for cutting, coagulation, and tissue modification

Endoscopy Devices

Flexible systems for visualization and intervention

Drug Delivery Systems

Devices designed for targeted therapeutic delivery

Implantable Sensors & Electrodes

Components used for monitoring and stimulation

These segments represent a portion of the medical applications ProPlate supports. Additional device types and specialized applications may also benefit from precision plating solutions.

Medical Coating Case Studies & White Papers

Gold-Plated NdFeB Magnets for Biocompatible Implant Applications

Gold plating services on magnets - medical coating solutions

NdFeB magnets require protective coatings for medical use due to their porosity and susceptibility to corrosion. ProPlate developed a multi-layer Ni-Cu-Ni-Au coating process that provides strong adhesion and corrosion resistance without damaging the base material. The result was a biocompatible surface capable of withstanding aggressive corrosion testing and meeting short-term implant performance requirements.

Download Case Study PDF →

The Product: Neodymium Iron Boron Magnets

Neodymium Iron Boron Magnets are one of the most powerful commercial permanent magnets available today. These rare earth magnets can be up to 10 times stronger than the strongest ceramic magnet. NdFeB magnets are typically produced using one of two general method categories, bonded magnets (compression, injection, extrusion, or calendaring molding) and sintered magnets (powder metallurgy, PM process).

The Challenge

ProPlate® worked with a medical customer who needed to achieve a biocompatible protective surface for NdFeB magnets used in a short-term implant application. Due to the porosity of the base magnet material combined with the reactivity of the magnets to acidic and basic chemistries, ProPlate® faced a difficult challenge designing a plating process for the Neodymium magnets. Throughout the plating process, adequate adhesion is necessary to use acidic and basic chemistries to remove surface oxide, which NdFeB rapidly forms without any protective coatings. Furthermore, proper handling of the magnets added more complexity to the project to ensure the magnets wouldn’t oxidize in the process steps or in the queue to be plated.

The Engineered Solution

Major obstacles ProPlate® faced were finding the precise balance of chemicals to use during the plating process and finding the most effective electroplating technique for uniform deposition and leveling to combat porosity. The key was to develop a chemical process aggressive enough to promote the best adhesion but mild enough for the base material to not corrode. Various plating methods using specific agitation, custom fixtures, and plating apparatuses were required to address the porosity. After numerous trials, the optimized process used a combination of Nickel and Copper layers followed by Gold; Nickel-Copper-Nickel-Gold. Gold is the ideal final layer because Gold is a commonly used bio-compatible metal in the medical device industry, and it offers superior corrosion protection due to its inertness. Using an aggressive accelerated corrosion test, ProPlate® tested the plated magnets to validate that the magnets could withstand a final series of corrosion testing like its intended use in the human body. An unprotected magnet would show signs of corrosion almost immediately in an accelerated corrosion test. ProPlate’s magnets, in some instances, have lasted months in this corrosive environment, which far exceeds the typical application requirements.

Benefits:
  • Eliminate Corrosion
  • Eliminate Porosity
  • Biocompatible
  • Hermetically Sealed
  • Atomically Bonded
  • Radiopaque
Applications:

Computer Hard Drive Magnets • Microphones • Headphones • Dentures • Loudspeakers • Magnetic Pump Couplings • Door Catches • Magnetic Suspension • Motors & Pumps • Generators • Sensors • Orthopedics • Halbach Arrays • Healthcare • MRI and NMR applications • Magnetic Separators • TWT (Transverse Wave Tube) • Magnetic Bearings • Lifting Apparatus • Limpet Pot Magnets • Starter motors • ABS systems • Fans Eddy Current • Brakes • Alternators • Meters • Magnetic Clamps • Magnetic Levitation • Electro-acoustic pick-ups • Switches • Relays • Catheter assemblies and components • Catheter tips • Surgical components and minimally invasive devices • Endoscopic assemblies • Hard disk drives • Electric motors in cordless equipment • Fasteners

Featured Article:

Gold-Plated Ni-Ti Interfaces for Reliable Dissimilar Metal Joining

Medical Coating Solutions

Joining Nitinol to dissimilar materials presents challenges due to poor weldability and surface oxidation. ProPlate developed a selective gold plating process to create a fusible interface between Ni-Ti and stainless steel components. The result was improved weld strength, reduced manufacturing complexity, and cost savings without compromising device performance.

Download White Paper PDF→

The Product: Fusing Ni-Ti to Dissimilar Materials

Ni-Ti handles continuous distortion and kinking. It presents many advantageous properties, such as super-elasticity, corrosion resistance, and bio-compatibility. In addition, the shape, stiffness, and other properties of Nitinol can be controlled by chemical composition, heat treatment, and temperature.

The Challenge

Ni-Ti is a versatile material but has rather difficult weld-ability and is expensive. For many medical applications, it is beneficial to use Ni-Ti for only a portion of the device and weld a different, less expensive material such as stainless steel for the remaining portion of the device. This combination enables cost reduction because of Nitinol’s high cost and provides for manufacturing improvements. It is commonly known that the disadvantages of Ni-Ti are difficult machine-ability because of its elasticity and hard surface and problematic weld-ability.

The Engineered Solution

After a complete analysis of the manufacturing process, a custom plating process was developed by ProPlate® to Gold plate the ends of the Ni-Ti and Stainless Steel components before welding. Custom tooling was used to mask and plate the device within quality specifications. Nitinol oxidizes naturally, which inhibits a weld from adhering correctly, but adding Gold to each end of the device allows for a fusible area between the two components. This innovative solution saves costs without sacrificing part performance while increasing tensile strength. Additionally, the applied Gold can be used as a radiopaque marker for specific applications.

Benefits:
  • Reduce Material Costs
  • Increased Tensile Strength
  • Improve Manufacturability
  • Maintain Performance & Quality Standards
Featured Article:

Consistent Silver Plating for Bipolar Forceps Performance

medical coating solutions - silver forceps

Bipolar forceps require uniform silver plating to ensure reliable thermal conductivity, but inconsistent coating led to high scrap rates and additional finishing. ProPlate developed a controlled plating process with custom tooling to deliver consistent silver coverage on the forceps tips. The result was improved product quality, reduced waste, and increased production efficiency.

Download Case Study PDF →

The Product: Bipolar Forceps 

Bipolar Medical Forceps are similar to normal surgical forceps in shape, but the intended purpose is much different. Unlike surgical forceps, which are meant to open and hold tissue, bipolar forceps are meant to coagulate, or make solid or semisolid, tissue using an electrical current. This electrical current is fired through the tips of the bipolar forceps requiring a metal finish to complete the thermal conductivity.

The Challenge

Three organizations were selected to design, manufacture, plate, and finish the Bipolar Medical Forceps for the OEM. In order to provide for thermal conductivity, a heavy layer of Silver was required. The existing plater was not able to provide consistent Silver plating, which drove additional downstream finishing by the fabricator. Additionally, 25% of plated forceps were considered unusable and disposed of, causing production problems for both the finishing partner and OEM.

Engineered Solution

ProPlate® worked closely with the engineers at the fabricator to determine manufacturing and Silver plating requirements for thermal conductivity. After a complete analysis of the manufacturing process, a recommendation was provided to plate and package forceps for the finishing partner. A custom plating process was developed to ensure consistent Silver coverage on the tips of the forceps with minimal post finishing. Custom tooling was used to mask and plate the forceps within specification consistently. The fabricator was able to reduce the labor component of handling and finish poorly plated forceps, eliminate the cost of disposing of unusable forceps and meet the contractual demand requirements by both the finishing partner and OEM.

Benefits:
  • Thermal Conductivity
  • Reduce Tissue Adhesion
  • Reduce Labor Costs
  • Eliminate Waste
  • Eliminate Defects
  • Non-Stick Ablations

Palladium-Nickel Alloy Plating as a Cost-Effective Gold Alternative

Palladium-Nickel Plating Services

Gold and platinum offer strong electrical and corrosion performance but can be cost-prohibitive and prone to wear in certain applications. ProPlate utilized palladium-nickel alloy plating to provide a durable, conductive, and more cost-effective alternative with improved hardness and reduced porosity. The result was a reliable solution for medical and electronic components that maintained performance while reducing material costs.

Download Case Study PDF →

The Product: Electroplated Palladium-Nickel Alloy

Nickel is known for ductility resistance. When combined with Palladium, the result is an alloy that has great stress and heat resistance, corrosion resistance, electrical conductivity, ductility, and solderability. The use of Pd-Ni became popular in the 1970s when scientists discovered the contact resistance, wear properties, and protective values of the alloy. Pd-Ni is a dense deposit; as a result, it offers reduced porosity and excellent solderability characteristics. Electrodeposited Palladium-Nickel alloys have a density between 10 and 11.5 g/cm3, which is noticeably less than electroplated Gold ~17.0 to 19.3 g/cm3 and comparable to electroplated pure Palladium ~10.5 to 11.8 g/cm3.Type II Palladium-Nickel alloy plating is composed of approximately 20% Nickel & 80% Palladium. This combination makes it less likely to crack or break under stress and, in turn, makes it more resistant to galvanic corrosion and heat than pure Palladium. It also has better ductility and hardness. The hardness of plated Palladium-Nickel measures favorably in comparison to other electroplated noble metals. For example, the approximate hardness of Pd-Ni is 300–650, Gold (HK25) is 50–250, Palladium is 75–600, Platinum is 150–550, and Rhodium is 750–1100.

The Challenge:

When looking for a metal or alloy that offers characteristics like Gold but is more cost-effective than Palladium, Palladium-Nickel is an excellent alternate solution. In both the medical and electronics industries, Gold and Platinum can be used for electrical conductivity, ductility, and corrosion resistance. Unfortunately, since Gold and Platinum are expensive metals, engineers often look for a lower-cost alternative. Pure Gold is often used for electrical contacts, but due to its softness, it will burnish and wear if there is mechanical movement in the application, such as a sliding contact or a battery contact that requires the replacement of the batteries. Palladium is another option for electrical contacts; it has a higher mechanical wear resistance than pure Gold, but when plated too thick, it often cracks from stress in the deposit. To avoid this problem, an alternative solution is to alloy Palladium with a more ductile metal that still has a reasonable hardness value, such as Nickel.

The Engineered Solution:

When looking for a metal alloy with a reasonable hardness value (that is still ductile and conducts electricity well), Palladium-Nickel is an excellent solution. Due to low surface contact resistance, Pd- Ni is often plated onto a base material such as Copper or stainless steel, sometimes prior to a thin layer of Gold; this combination results in a low-cost, stable solution. In the medical industry, Pd-Ni can be used as both an underlayer and a final layer. Palladium-Nickel can be used on medical devices such as stents, pull rings, catheter shafts, and Nitinol-based complex geometries. Palladium-Nickel does not distort magnetic resonance images and allows for more flexibility on medical devices than pure Palladium. Pd-Ni is commonly electroplated onto connectors and battery contacts and remains a valuable alternative to Gold or pure Palladium in the electronics and medical device industry for these reasons. Lastly, Pd-Ni can be used in the dental industry. Like Gold, Palladium is not toxic; in the dental industry, it can be an excellent choice for products such as bridges, inlays, and crowns and can be used for aesthetic purposes in the orthodontic industry.

Benefits:
  • Excellent Wear Resistance
  • High Level of Brittleness
  • Very Conductive
  • High Heat Resilience
  • Solderability
  • Very Hard Finish

Gold Plated Copper Targets for Radiopharmaceutical Production

Gold plated rectangle target

Gold-plated copper targets used in cyclotron-based radiopharmaceutical production required enhanced durability, corrosion resistance, and thermal performance to maintain isotope purity and operational efficiency. ProPlate developed precision gold plating processes with controlled thickness and selective application to withstand high-energy irradiation and harsh chemical environments. The result was improved Cu-64 production yield, extended target lifespan, and reduced downtime for radiopharmaceutical manufacturers.

Download Case Study PDF→

Client – Radiopharmaceutical Manufacturers and Cyclotron Operators

Gold-plated copper targets are indispensable in radiopharmaceutical manufacturing, particularly in the production of high-purity medical isotopes such as Copper-64 (Cu-64). These targets are critical components in cyclotron systems, where their precision, durability, and efficiency enable the consistent production of radiopharmaceuticals used in diagnostics and therapeutics. Gold-plated copper targets are engineered to perform under extreme conditions encountered in radiopharmaceutical production:

  • Beam Currents: Capable of withstanding currents exceeding 200μA.
  • Proton Energies: Effective at energies ranging from 15 to 30 MeV.
  • Thermal & Chemical Durability: Resistant to elevated temperatures and corrosive dissolution processes.

ProPlate® specializes in advanced gold and selective gold plating techniques, ensuring that copper targets meet the stringent requirements of this high-stakes industry. This white paper explores the applications, benefits, and technological advancements behind ProPlate’s solutions for radiopharmaceutical production.

The Challenge

In cyclotron-based radiopharmaceutical production, copper targets plated with gold (or silver) serve as substrates for generating isotopes like Cu-64. The production process involves high-energy proton bombardment of nickel (Ni) or other enriched materials layered on these targets. However, this process presents several challenges:

  • Corrosion Resistance: Bare copper is susceptible to oxidation and corrosion, affecting isotope purity.
  • Thermal Management: High-energy irradiation generates significant heat, necessitating effective heat dissipation.
  • Chemical Purity: Unprotected copper surfaces can introduce contaminants, impacting pharmaceutical quality.
  • Durability: High-energy bombardment degrades unprotected targets, reducing operational lifespan.

The Engineered Solution

ProPlate® employs state-of-the-art electroplating techniques to produce thick, uniform gold layers tailored for radiopharmaceutical applications. Our process emphasizes precision and quality at every step:

  • Surface Preparation: Rigorous cleaning and preparation of copper substrates to optimize adhesion.
  • Selective Gold Plating: Advanced fixturing and masking techniques ensure precise deposition, minimizing material waste.
  • Controlled Electroplating Parameters: Bath composition, current density, and voltage are meticulously managed to create a uniform and durable gold layer.

A ProPlate® customer in radiopharmaceutical production reported the following improvements using our gold-plated copper targets:

  • Yield Increase: Cu-64 production efficiency improved by 15%, reducing isotope shortages.
  • Cost Savings: Targets with superior durability allowed for multiple production cycles, minimizing material costs.
  • Operational Uptime: Enhanced durability and ease of decontamination reduced downtime by 30%.

ProPlate®’s gold plating and selective gold plating solutions are transforming the landscape of radiopharmaceutical production. By delivering precision-engineered, durable, and reliable copper targets, we empower manufacturers to produce isotopes like Cu-64 with unparalleled efficiency and quality.

Benefits

  • Yield Increase
  • Costs Savings
  • Reduce Operational Downtimes

Selective Gold Plating for Insulin Pump Battery Casings

Medical Coating solutions -insulin pump image

Selective gold plating on insulin pump battery casings presented challenges with masking costs and palladium staining. ProPlate developed a custom plating process with specialized tooling and airflow control to achieve precise gold placement and eliminate defects. The result was a reliable, corrosion-resistant solution that reduced plating costs by 40% and supported production demands.

Download White Paper PDF→

The Product: Insulin Pump Battery Casing

The insulin pump is a medical device used to administer insulin in the treatment of diabetes mellitus, also known as continuous subcutaneous insulin infusion therapy. The pump includes controls, a processing module, and batteries. The battery casing at the left is designed to be corrosion resistant. In order to provide this, the casing must be plated in Nickel and Palladium and include a small strip of Gold.

The Challenge

The approved plater was not properly equipped to selectively plate Gold onto the battery casing. Options to mask the battery casing post Nickel and Palladium plating proved to be cost-prohibitive. Options were tested to plate Gold selectively, but Palladium staining could not be controlled inside or outside the battery casing.

The Engineered Solution

ProPlate® worked closely with the engineers at the fabricator to determine manufacturing and plating requirements for corrosion resistance. After a complete review of the requirements and challenges faced by the fabricator and downstream finishing partner, a custom plating process was developed to meet plating requirements. Custom tooling was designed to plate Gold selectively, and an engineered airflow management system was created to prevent gas staining. The ProPlate® engineered solution reduced the overall cost of plating by 40% and provided a production environment to meet quantity demands.

Benefits:
  • Corrosion Resistant
  • Reduce Plating Costs
  • Eliminate Stains

Frequently Asked Questions About Medical Coating Solutions

Medical coating solutions are engineered metal layers applied to medical device components to enhance performance without altering the core design or geometry of the part. Coatings enable functionality such as electrical conductivity, corrosion resistance, radiopacity, and improved durability, particularly in catheter-based and minimally invasive devices where component size and geometry are critical constraints.

ProPlate selectively applies precious and semi-precious metals including gold, platinum, palladium, palladium-nickel, and silver to medical device components. The appropriate metal depends on the application’s requirements for conductivity, biocompatibility, corrosion resistance, radiopacity, and cost.

Yes. ProPlate has developed processes to gold plate Nitinol and stainless steel components, creating a fusible interface that allows the two materials to be welded together despite Nitinol’s natural surface oxidation. This approach improves weld strength, reduces manufacturing complexity, and lowers material costs by minimizing the amount of Nitinol required.

Yes. Palladium-nickel alloy plating provides electrical conductivity, corrosion resistance, and wear resistance comparable to gold at a lower material cost. It is commonly used on stents, pull rings, catheter shafts, and Nitinol-based components, and does not distort magnetic resonance images, making it suitable for MRI-compatible device applications.

Yes, with proper protective coatings. NdFeB magnets are porous and highly susceptible to corrosion in their unprotected state. ProPlate developed a multi-layer nickel-copper-nickel-gold coating process that provides strong adhesion and corrosion resistance, validated through accelerated corrosion testing, making the magnets suitable for short-term implant applications.

Yes. ProPlate’s engineering team works directly with medical device manufacturers to develop custom plating processes, masking systems, and tooling for specific application challenges. Examples include selective gold plating for battery casings, consistent silver plating for thermal conductivity applications, and corrosion-resistant coatings for porous substrates.
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