Corrosion Protection for Implants


Leading Medical Device Company.


Implantable devices were failing due to in-body corrosion. Their small size and complexity made coating difficult.


VSi created a custom-developed process to provide a thin film parylene moisture barrier.


VSi delivered the product within weeks, and the client saw an immediate reduction of device failures.

The Issue

A leading medical device company contacted VSI when their devices started to fail in the field. They found corrosion on a micro-connector that sent signals from a long-term implant to external electronics. The corrosion blocked the accuracy of the signal. The companies reputation was at stake as the patients lost trust in the device.

Moisture from the user’s body and the environment was the source of the corrosion. They needed a way to protect the connector from the environment. Engineers explored using parylene as a barrier layer to protect the metal connectors. The team liked that adding parylene didn’t require any significant design changes and it has a proven history for use in medical devices.

This application was beyond the limits of other parylene vendors because of the small size and complexity. The micro-connector had an array of sockets that were less than 0.5 mm in diameter. Parylene needed to protect the exterior surfaces from moisture but the ID of the sockets needed to remain uncoated to allow electrical signals to pass.

The Results

VSI proved to be uniquely qualified to solve the problem. With extensive experience in coating small, complex parts and VSi used the “Total Solution” development process to find a solution in record time.

This project became a top priority and VSi worked with the customer to find a solution. VSi got to work with iterative coating runs, rapid turn-arounds and personal attention. At the same time, our customer provided useful feedback and was busy testing solutions. With a combined effort, VSi developed, tested and validated the solution in weeks.

VSI designed the parylene coating process with scale in mind. When the green light was given, they were ready with dedicated resources and trained staff. VSi kept working with the customer to match capacity to demand and find ways to keep improving.

The Impact

By rapidly developing a solution with the customer, VSi helped build a more reliable product that patients can trust. The elegant solution was put into place quickly and there weren’t any major changes to the device design. VSi Parylene remains a proud part of the critical medical device supply chain that improves the everyday lives of thousands of people.

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