In the fast-changing field of medical device technology, having good performance, reliability, and efficient processing is very important. With the introduction of HydrUV™, a new UV-curable hydrophilic coating from Hydromer®, Inc., medical coating technology has reached a new level. Our new UV medical coating provides enhanced durability, faster processing times, and long-lasting hydrophilicity. This coating is ideal for applications where efficiency, reliability, and consistent performance are mission-critical.
In this article we discuss what UV-curable medical coatings are and their benefits. We also dive into our new HydrUV, which is the newest addition to our extensive medical coatings line.
The Need for Next-Gen, UV Hydrophilic Coatings
Medical devices like catheters, and guidewires require surface modification so they are safe for use inside the body. They also need to be low friction, having the ability to slide easily against tissues and complex pathways. Biocompatible, hydrophilic coatings are slippery when wet, lubricious coatings. They make it easier to insert and navigate medical devices, increase patient comfort, and create better patient outcomes during procedures.2,3
However, not all hydrophilic coatings are created equal. Some coatings in the market have their problems. For instance, some take a long time to cure, reducing efficiency. Others adhere differently on various substrates. And some have low durability performance.4
HydrUV was created to address these issues. This new coating uses advanced UV-curable chemistry, ensuring efficient curing and high performance without any compromises.
What Is UV Curing And Why It Matters in Hydrophilic Coatings?
UV curing is a process that uses ultraviolet (UV) light to quickly harden hydrophilic coatings. When the coatings are exposed to UV light, especially in the UV-A range (315–400 nm), they transition from a liquid to a solid. And the process happens almost instantly, often in just a few seconds. 5,6
This method is different from thermal curing, which requires high heat and longer processing times. If a product is a fit for a UV coating then there are some benefits vs thermal curing. UV curing is not only faster, but it is also more energy-efficient. The result is a coating with long-lasting hydrophilicity and enhanced durability that can be processed quickly and efficiently.
Choosing between UV and thermal coatings will depend on the application, device materials, and performance requirements. You can learn more in our guide UV Coating vs Thermal Coating Review: Which One Should You Choose?
Mechanism of UV Curing: How Does UV Curing Work
UV curing involves three main components. These include the following:
- Oligomers and Monomers: These are the base molecules in the coating formulation that will form the final polymer network.
- Photo-initiators: Light-sensitive compounds that absorb UV energy and initiate a chemical reaction.
- UV Light Source: Typically within the UV-A range (315–400 nm) for safer and more material-compatible curing.
UV Curing Process
Here’s how the UV Curing process works:
- UV light irradiates the coating, and the photo-initiator absorbs this energy.
- The photo-initiator undergoes photo-decomposition, releasing highly reactive species like free radicals or cations.
- These reactive species start rapid chain polymerization of the monomers and oligomers, forming a cross-linked polymer network.
- The result is a solid, flexible, and chemically bonded coating that adheres tightly to the substrate (in this case the medical device).
This entire transformation has the potential to occur in less than a second, depending on the intensity of UV light and the formulation of the coating.
If you want to learn more about UV Coatings in the medical space, make sure to read our guide on UV Curing for Medical Devices: Role of PEG, PVP, Chitosan.
Why UV Curing is a Fit for Hydrophilic Medical Coatings 6
The UV-curing mechanism offers many advantages for hydrophilic coatings like Hydromer’s HydrUV.
These include:
- Controlled cross-linking creates a dense, durable network that resists wear and delamination.
- The polymer structure can be engineered to retain hydrophilic functional groups, which draw and retain water at the surface, resulting in exceptional, long-lasting lubricity.
- Moisture-activated surfaces becomes slick when in contact with bodily fluids, making them ideal for medical devices that must navigate through soft tissue or vessels with minimal resistance.
Fast and efficient UV curing turns HydrUV from a liquid into a durable, lubricious coating, optimized for modern medical device performance.
What Sets HydrUV™ Apart From Other UV Medical Coatings?
HydrUV is a UV-curable hydrophilic, medical coating system. It is engineered for medical applications where processing efficiency, durability, and consistent performance are non-negotiable.
It is not just another medical coating. It is a precision-engineered solution designed to meet the specific demands of the most challenging medical environments. Hydromer has tailored every element of this UV-coating to boost product performance across the board. 1
Here is what sets HydrUV apart from other UV-cure medical coatings.
Enhanced Durability
- The HydrUV UV coating boasts long-lasting mechanical and lubricious properties
- It shows consistent performance even under repeated mechanical stress
Faster Processing Time
- HydrUV provides fast curing using UV-A light, which is in a safer spectrum range.
- Curing technology allows device manufacturers to reduce processing times while maintaining quality.
- It increases production efficiency and minimize delays in the manufacturing process.
Long-Lasting Lubrication
- Once cured, HydrUV retains its lubricating properties for a significant time, allowing devices to work as intended during their medical use.
- This feature is important for procedures that are sensitive in nature and require less damage to tissues.
Versatile Application Across Many Substrates
- HydrUV offers strong adhesion and dependable performance across many different products.
- Product has been tested on a wide range of substrates, including metals and various types of plastics. These include Nylon, Polyethylene Terephthalate Glycol, Thermoplastic Polyurethane, Polyether Block Amide (PEBAX), and others.
Precise and Safer Curing Technology
- Our coating is designed to use UV-A light. This means it can work effectively without putting materials or people at risk.
HydrUV™: A Coating Solution For Many Substrates
A major benefit of our UV coating is that it is compatible with such a wide range of substrates. This allows the coating to be used on many devices and materials.
In lab tests, HydrUV showed an ability to adhere to surfaces, provide an even coating, and have high durability on common materials used in medical devices. These materials/substrates include:
- Nylon
- PETG (Polyethylene Terephthalate Glycol)
- TPU (Thermoplastic Polyurethane)
- Polyether Block Amide (PEBAX)
- Polypropylene (PP)
- Polycarbonate (PC)
- and more.
In mechanical performance testing HydrUV UV coatings showed steady pull force over 50 cycles on many different substrates. The results show the coatings have strong adhesion and coating strength, even when faced with repeated movement and stress.
This performance is important for uses like indwelling catheters or guidewires, which operate in changing environments.
HydrUV’s ability to be used on so many different substrates provides device manufacturers with more design freedom. Preferred base materials can be used without sacrificing the advantages of high-quality coating technology. HydrUV provides the durability and performance your device requires. This is true whether you are creating flexible catheter shafts, stiff connectors, or uniquely shaped parts.
HydrUV™ Streamlines Production & Increases Efficiency
HydrUV coatings can help simplify and speed up your coating process. This is especially true when compared to other curing processes, such as thermal curing. Our UV coatings:
- Seamlessly integrate into automated production lines
- Reduce bottlenecks by eliminating lengthy oven cure steps
- Improve coating uniformity on complex geometries
- Minimizes rework and quality control failures
Safe and Precision Curing Using UV-A Light
Traditional, high-energy UV systems can cause problems, such as damaging materials or posing safety risks to workers. Hydromer HydrUV is designed to cure effectively using UV-A light, a safer range of the spectrum.
This feature ensures:
- Improved occupational safety
- Lower thermal stress on substrates
- Uniform curing, even on complex geometries
Medical Applications Where HydrUV™ Shines
HydrUV is a good fit for many medical devices. In particular it is a fit for ones that require smooth, lubricious surfaces, entail frequent movement/navigation, and biocompatibility.
Example medical device applications include:
- Urological and cardiovascular catheters
- Central venous access devices
- Minimally invasive surgical tools
- Interventional radiology instruments
- Diagnostic tubing and sensors
Contact our coating experts if you are unsure whether HydrUV is suitable for your device. We offer many customizable, medical device coatings in addition to our UV-curable line.
Hydromer®, Inc.: A Trusted Partner in Coatings Innovation
Hydromer, Inc. is a US-based, hydrophilic coatings manufacturer. For over 40 years we have created coating technologies that enhance the safety, effectiveness, and user experience of our partners’ medical devices.
Our HydrUV UV coatings are the newest addition to our coatings portfolio. It was created to provide a solution that is both advanced and practical for real-world manufacturing settings.
Hydromer can develop a customized and innovative coating solution for your product.1 So whether you are looking to increase production efficiency, improve coating reliability, or meet strict product performance requirements, we can help. We have a full portfolio of medical device coatings, including both thermal and UV-cure options.
Request Samples, Test HydrUV™ Yourself
Interested in testing our coatings for your application? We can provide sample kits and a technical consultation for our coating products, including our new HydrUV. We also offer contract R&D services, as well as contract coating and technology transfer services.
Contact us for more information, to order samples, or to schedule a conversation with our team.
Final Thoughts
Hydromer HydrUV™ represents a significant advancement in medical device coatings. This new coating leverages UV-curable hydrophilic technology to address critical industry needs. It offers enhanced durability, rapid processing, and sustained lubricity, proving ideal for devices requiring consistent, high-performance surface modification. By streamlining manufacturing and ensuring reliable performance across diverse substrates, HydrUV improves patient safety and comfort as well as product performance.
References
Click to see references for this article.
1. Hydromer. Medical Device Coatings. Hydromer. https://hydromer.com/medical-device-coatings/
2. Kiemeneij F, Fraser D, Slagboom T, Laarman G, van der Wieken R. Hydrophilic coating aids radial sheath withdrawal and reduces patient discomfort following transradial coronary intervention: A randomized double‐blind comparison of coated and uncoated sheaths. Catheterization and cardiovascular interventions. 2003;59(2):161-164.
3. Niemczyk A, El Fray M, Franklin SE. Friction behaviour of hydrophilic lubricious coatings for medical device applications. Tribology International. 2015/09/01/ 2015;89:54-61. doi:https://doi.org/10.1016/j.triboint.2015.02.003
4. Burns J, Pollard D, Ali A, McCoy CP, Carson L, Wylie MP. Comparing an Integrated Amphiphilic Surfactant to Traditional Hydrophilic Coatings for the Reduction of Catheter-Associated Urethral Microtrauma. ACS Omega. 2024/05/21 2024;9(20):22410-22422. doi:10.1021/acsomega.4c02109
5. Soucek MD, Ren X. UV-Curable Coating Technologies. In: Tiwari A, Polykarpov A, eds. Photocured Materials. The Royal Society of Chemistry; 2014:0.
6. Sabel-Grau T, Tyushina A, Babalik C, Lensen MC. UV-VIS Curable PEG Hydrogels for Biomedical Applications with Multifunctionality. Gels. Mar 5 2022;8(3)doi:10.3390/gels8030164
