The manufacturing of mesh plates for inhalation devices typically relies on laser drilling, a process that leaves behind molten metal residue and jagged rims around micro-holes. These loose particles pose a health risk if inhaled, and their presence can cause unpredictable flow rates or droplet size drift. Piezo Direct has introduced a proprietary post-processing technique that strips away this debris without compromising the integrity of the titanium mesh or the precision of the 2.0-micron holes.
Piezo Direct Eliminates Particulate Debris in Mesh-Based Atomizers
Burlingame-based Piezo Direct has unveiled a mesh-based piezo atomizer designed to eliminate the microscopic metal debris inherent in traditional laser-drilling processes. By removing the recast rim—often called the "volcano"—the company aims to increase safety for users of nebulizers, inhalers, and high-precision vaping devices.
According to CEO Li Hsu, the company prioritized the removal of these residues to prevent potential lung damage from detached metal shards. Beyond safety, the technology maintains a strict diameter tolerance of ±0.3 microns, which is essential for ensuring droplets remain within the 3.0 to 4.2-micron range required for deep respiratory delivery. The titanium-based components are designed to withstand aggressive drug formulations and high-frequency vibrations exceeding 100 kHz. These atomizers are currently available for medical, consumer, and industrial applications, with future development cycles already focused on achieving sub-1.5-micron hole sizes.
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