Mayer Rod Applicators
High quality Mayer Rods available as both wire wound and formed for highly reproducible thin films
Ossila offer a range of Mayer Rod Applicators which can be used to form consistent thin film coatings. We offer them as either wire wound where the bar is wound with a wire, or formed where a groove is machined into the bar. Both types are available in a wide range of coating thicknesses and are made from corrosion resistant stainless steel.
Wire-Wound Rod
Wire-wound Mayer rods consist of a central metal rod with a wire of a specific diameter wound around it. The gaps formed between the wires and the substrate determine the coating thickness. Therefore the wet-film thickness can be estimated from the diameter of the wire and the packing of the wires.
For most wire-wound Mayer bars the wire is closely packed, this means that ideally there is no gaps between the wires. In this situation the wet-film thickness can be easily approximated and is given by the diameter multiplied by a geometric factor of 0.10731, the below table gives the upper wet-film thickness for each diameter of wire.
| Wire Diameter | Wet Film Thickness | Wire Diameter | Wet Film Thickness |
| 0.06 mm | 6 µm | 0.47 mm | 50 µm |
| 0.10 mm | 10 µm | 0.56 mm | 60 µm |
| 0.11 mm | 12 µm | 0.65 mm | 70 µm |
| 0.14 mm | 15 µm | 0.75 mm | 80 µm |
| 0.19 mm | 20 µm | 0.93 mm | 100 µm |
| 0.24 mm | 25 µm | 1.22 mm | 120 µm |
| 0.28 mm | 30 µm | 1.40 mm | 150 µm |
| 0.37 mm | 40 µm | 1.86 mm | 200 µm |
Formed Rod
Formed Mayer Rods have a groove machined into the rod that mimics the gap that is present between the wires in a wire wound rod. The advantage of extruded rods are that they are less prone to damage, they are less prone to contamination, and the packing density of the grooves can be easily controlled unlike with wire wound bars. However, formed rods tend to be more expensive due to the complexity involved in manufacturing to such tight tolerances.
Formed rods don't have conversion tables for wire diameter to wet film thickness, instead the shape of the groove and the width of the crest between grooves is controlled to provide the targeted wet film thickness. The standard thicknesses that are made with formed rod follow those available for wire-wound rods to allow users to easily adapt coating processes to these new types of rods.
End Machining
Ossila can provide customers with end machining that suits their needs. As standard all our Mayer Rods come with M4 tapped ends. This provides maximum adaptability of the bar across multiple applicators.
Mayer Rod Sets
Ossila also sell full sets of Mayer Rods giving you full flexibility to your coatings. The set can either be the wire-wound variety or formed. The set includes all available coatings thicknesses, and when buying as a full set you save over 20% of the cost compared to buying them individually.
Specifications
| Specification | Wire-Wound | Formed |
| Coating Width | 200 mm | |
| Coating Thickness | 6µm, 8µm, 10µm, 12µm, 15µm, 20µm, 25µm, 30µm, 40µm, 50µm, 60µm, 70µm, 80µm, 100µm, 120µm, 150µm, 200µm | |
| Rod Material | 304 Stainless Steel | |
| End Machining | M4 Tapped | |
| Total Width | 240 mm | |
| Rod Diameter | 9.9 mm | 8.6 mm |
Resources and Support
Bar Coating: Methods, Theory, and Application
Bar coating is a simple wet processing technique used to deposit a thin layer of solution.
Read more...
Doctor Blade Coating: Methods, Theory, and Design.
Doctor blade coating is a common technique used to apply a thin, uniform layer of solution onto a substrate. The process involves using a blade to spread a coating of solution across a surface.
Read more...