ElectroBond® Electrosurgical Blade Coating
ElectroBond® is a PFAS-FREE coating specifically formulated for high-temperature applications requiring non-stick performance and electrical insulation. It allows electrosurgical cutting devices to work more efficiently and consistently. ElectroBond® is an extremely durable, black, smooth, low-friction medical coating that permanently bonds to metal surfaces, including 300 and 400 series stainless steel.
ElectroBond® is a PFAS-FREE electrosurgical blade coating engineered to replace PTFE on high-temperature surgical devices. Its epoxy/silicone composite bonds permanently to stainless steel, resists eschar buildup, and provides electrical insulation, enabling electrosurgical blades, jaws, and probes to cut more cleanly and consistently than standard PTFE-coated alternatives.
Optimizing Non-Stick Electrosurgical Device Performance
Electrosurgical blade coatings must withstand extreme heat and prevent the buildup of eschar, burned tissue that roughens blade edges and reduces cutting precision. ElectroBond® was developed specifically to address these performance failures in PTFE coatings, providing a smooth, pore-free, non-stick surface that resists damage and maintains controlled cutting.
In the past, the PTFE coating on endoscopic electrosurgical blades was not effective in preventing the buildup of eschar (burnt tissue) during surgical procedures, resulting in blades roughened by the adherence of tissue. Manufacturers needed a non-PTFE coating for their stainless electrosurgical blades.
In response to this problem, the SSG team has developed a durable No PTFE/PFAS-FREE, high-temperature release coating material. ElectroBond® repeatedly succeeds in providing a smooth non-stick, pore-free surface. Unlike the PTFE surface of standard electrosurgical blades and devices (ball, wire, needle, etc.), ElectroBond® resists damage and scratching.
The SSG team has completed all of the 510K certification documentation required for ElectroBond® to receive FDA approval for these electrosurgical device blades and manufacturers now have internationally qualified ElectroBond® electrosurgical coated blades that overcome the performance problems inherent in PTFE coatings.
How ElectroBond® Solves Eschar Buildup on Surgical Blades
ElectroBond® eliminates eschar buildup by creating a smooth, non-stick, pore-free surface that does not allow burned tissue to adhere during electrosurgical procedures. FDA 510K certification documentation has been completed for ElectroBond® electrosurgical blade applications, and the coating is internationally qualified for mono-polar and bi-polar devices.
Key Features & Properties of ElectroBond®
ElectroBond® offers 4H pencil hardness, resistance to temperatures up to 700°F continuous and 840°F short term, and zero porosity for controlled cutting with virtually no uncontrolled sparking. It withstands gamma radiation sterilization up to 100 kGy and is the most damage-resistant electrosurgical coating currently available.
- Extremely hard surface (4H pencil hardness) with excellent eschar release
- No porosity provides controlled cutting with virtually no uncontrolled sparking
- More damage resistant than any PTFE or silicone electrosurgical coating on existing blades
- High temperature resistant; 700°F continuous and 840°F short term stability
- Will not thermally decompose during use and does not develop hot spots
- Is a tough, yet resilient coating developed from an epoxy / silicone composite
- Most physically durable and damage resistant electrosurgical coating available
- Certified formulations available containing no PTFE or PFAS
- No C5 or phosgene effluent or coating decomposition smoke
- Withstands gamma radiation sterilization with no change in performance; 100kgy for verification; 25~kgy in production
- Successfully bonded to blades, needles, wires, balls, probes, and more
- Bonds to any metal surface on both mono-polar and bi-polar devices
Electrical Properties & Custom Formulations
ElectroBond® electrosurgical coating is available in low-power, high-conductivity formulations for procedures requiring precise energy delivery at reduced power settings. Custom formulations support both mono-polar and bi-polar devices, making it adaptable to a wide range of electrosurgical instrument designs and clinical applications.
- Low power setting / high conductivity formulations available for low power settings
Details of Edge & Tip Optimization
ElectroBond® can be applied at variable thicknesses from .0003″ to .003″ per surface, with precise deposition at tips and edges for optimum cutting performance. Low starting power formulations are available for delicate procedures, and clean-area masking keeps non-coated zones free of any coating bleed.
- Low starting power requirement formulations and application are available for delicate procedures
- Can be deposited at variable thickness options for optimum performance
- Bonded coating thickness available from .0003” to .003” per surface
- Areas of coating application precisely deposited; tip / edge thin or clean areas available.
Dry Film Properties
ElectroBond® dry film is black with 4H pencil hardness and ranges from .0003″ to .003″ in thickness, or 7 to 75 microns. The raw materials are listed in FDA CFR Title 21, Parts 175 and 177, confirming suitability for regulated medical device applications.
- Color/hardness: Black/4H pencil hardness
- Dry Film Thickness: .0003″ to .003″ or 7 to 75 microns
The raw materials and resin systems are listed in the Code of Federal Regulations, Title 21, Food and Drugs, Parts 175 and 177 for materials suitable for food contact.