Ultrasonic nebulization-assisted layer-by-layer assembly for spray coating of multilayered, multicomponent, bioactive nanostructures

In this study, we describe a new technique for creating dense, stable, nanolayer coatings on solid substrates using ultrasonic nebulization. Nebulization-assisted layer-by-layer assembly (LbL) is a modification to the well-characterized LbL assembly method. The conventional method of producing electrostatically assembled multilayer films through sequential substrate dipping was compared to the nebulization method, and the resultant film characteristics were investigated. Varied coatings can be generated according to the alterations in deposition parameters, with the most influential being nebulizer distance and time. In addition to employment of polyelectrolytes (PEs), the nebulization method has been extrapolated to generate assemblies containing nanoparticles and a model drug, dexamethasone. It is shown that in comparison with conventional LbL, similar bilayers’ layering thicknesses can be achieved within a much smaller timeframe. Furthermore, PEs and more complex protein and nanoparticle assemblies can be incorporated to influence the surface topography and functionality. The potential to expeditiously assemble multicomponent films has far-reaching implications in many focus areas.