Advantages and disadvantages of full-length and segmental coating of long guidewires

There are two main methods in the process of coating medical long guidewires: full-length coating and segmented coating. Below is a description of these two processes and their advantages and disadvantages.

Full-length coating

Process Description:

Straight coating, also known as full-length coating, refers to the continuous application of one or more layers of coating material over the entire length of the guidewire. This method usually requires the use of a specialized coating machine capable of handling long guidewires and maintaining the uniformity and continuity of the coating.


  • Continuity: Straight coating ensures that the coating is continuous over the entire length of the guidewire with no seams or inconsistencies.
  • Productivity: Straight coating is often more efficient than split coating because the process is continuous and does not require multiple loads and unloads.
  • Coating Quality: Full-length coating reduces the number of joints in the material, which reduces potential weaknesses.


  • Equipment requirements: Direct coating typically requires longer lines and more advanced equipment, especially for extra-long guidewires.
  • Operational challenges: Long guidewires are prone to tangling during handling and coating, requiring special precision.

CatheterMelt Long guidewire coating machine belongs to full length coating.

Segmented Coating

Process Description:

Segmented coating involves dividing a long guidewire into shorter segments, coating them separately, and then connecting the segments to form a complete guidewire.


  • Lower equipment requirements: Segmented coating does not require particularly long equipment or production lines, making it suitable for production environments with low equipment investment budgets.
  • Operational Flexibility: Segmented coating is more flexible in terms of operation, making it easier to control the quality of the coating.
  • Suitable for special needs: if different parts of the guidewire require different coating materials or characteristics, segmental coating is a good choice.


  • Seam issues: Segmented coatings can have inconsistencies at the seams, and these areas can be potential weaknesses.
  • Low productivity: Compared to straight coating, segmental coating is less productive because it requires additional time and work to process each segment.
  • Coating continuity: Segmental coating may be difficult to achieve the same coating continuity and uniformity as straight coating.

In selecting a suitable coating process, consideration should be given to the end use of the guidewire, the desired coating properties, productivity, cost, and the investment and operating conditions of the equipment. Medical device manufacturers typically decide which coating process to use based on specific application requirements and production capabilities.

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