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Formed Mayer Rod - Precision Coating Bar

Formed Mayer Rod - Precision Coating Bar

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The S4R Formed Mayer Rod is a precision stainless-steel coating bar designed for controlled and repeatable laboratory wet-film preparation.

Unlike conventional wire-wound rods, the metering profile is formed directly into the solid rod surface, eliminating external wire winding and providing a durable coating surface that is straightforward to clean between formulations.

The standard configuration features a Ø10 mm rod, 240 mm overall length and 210 mm effective coating width. Eighteen nominal wet-film configurations from 4 to 200 µm cover applications ranging from thin functional coatings and separator treatments to battery electrodes, polymers and ceramic formulations.

Each rod corresponds to one fixed nominal configuration, eliminating adjustable gap settings between coating runs. The rod can be used directly by hand, with the optional weighted holder, or with compatible laboratory coating equipment.

The nominal value represents the rod's coating configuration and should not be interpreted as a guaranteed deposited wet- or dry-film thickness.

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Precision Bar Coating

Formed Mayer Rod — Precision Coating Bar

Formed stainless-steel coating rod with a 210 mm effective coating width and eighteen nominal wet-film configurations from 4 to 200 µm

Precision laboratory coating bar for controlled and repeatable wet-film drawdown. The metering profile is formed directly into the solid rod surface rather than produced by external wire winding, providing a durable coating surface with straightforward cleaning between formulations. Each rod carries one fixed nominal configuration, eliminating adjustable gap settings between coating runs.

Nominal WFT range
4 to 200 µm
Configurations
18 nominal values
Effective coating width
210 mm
Rod dimensions
Ø 10 × 240 mm
Product Highlights

Solid formed profile for controlled laboratory drawdown

A compact coating tool for laboratories that need a defined nominal configuration without the adjustment mechanism of a doctor blade.

01

Formed coating profile

The metering profile is formed directly into the solid rod surface, with no external wire winding to loosen or unwind.

02

Eighteen configurations

Nominal wet-film values from 4 to 200 µm cover thin functional layers through higher-build laboratory coatings.

03

210 mm coating width

The 240 mm rod provides a 210 mm effective coating zone for laboratory substrates and electrode sheets.

04

Straightforward cleaning

The formed profile can be cleaned directly after coating before the formulation dries within the metering grooves.

Available Configurations

Nominal wet-film thickness selection

Each rod corresponds to one nominal coating configuration. Select the rod according to the required coating range and formulation.

4 to 20 µm
Fine coating range

4, 6, 8, 10, 12, 15 and 20 µm for thin functional layers, membrane coatings and low-build formulations.

25 to 70 µm
General laboratory range

25, 30, 40, 50, 60 and 70 µm for routine coating development, formulation screening and comparative studies.

80 to 200 µm
Higher-build range

80, 100, 120, 150 and 200 µm for electrode coatings, ceramic formulations and higher-deposition layers.

Available nominal thicknesses 4, 6, 8, 10, 12, 15, 20, 25, 30, 40, 50, 60, 70, 80, 100, 120, 150 and 200 µm.
Choosing a Coating Tool

Coating rod or film applicator

Both architectures are useful in laboratory coating. The appropriate choice depends mainly on formulation behaviour, required thickness range and the level of adjustment needed.

Choose the coating rod

  • Fluid and low-to-medium-viscosity formulations
  • Thin and medium wet-film preparation
  • One fixed nominal value per rod
  • Fast changeover between predefined coating configurations

Choose a film applicator

  • Viscous or highly loaded slurries
  • Thicker coating builds or defined blade clearance
  • Adjustable gap where thickness must be swept or fine-tuned
  • Coating widths other than the standard 210 mm rod width
Product Data

Technical specifications

Parameter Specification
Product type Formed Mayer rod / precision coating bar
Construction Solid rod with formed coating profile
Material Stainless steel
Rod diameter Ø 10 mm
Overall length 240 mm
Effective coating width 210 mm
Nominal WFT range 4 to 200 µm
Available variants 18 nominal thickness configurations
Adjustment None; one nominal configuration per rod
Operation Manual, holder-assisted or compatible coating equipment
End protection Removable protective caps
Optional accessory Weighted stainless-steel rod holder
Typical Applications

Laboratory wet-film preparation

  • Battery anode and cathode coating
  • Separator and membrane coatings
  • Functional thin-film preparation
  • Polymer and ceramic formulations
  • Ink, paint and coating development
Optional Accessory

Weighted stainless-steel rod holder

The optional holder provides convenient one-handed handling and helps maintain consistent contact during manual drawdown. The rod can also be used directly by hand or integrated with compatible laboratory coating equipment.

Operating Guidance

Consistent drawdown starts with controlled handling

Use the rod on a clean, flat substrate and maintain consistent movement and contact conditions throughout the coating stroke.

01

Secure the substrate

Place the foil, film or substrate on a clean and flat coating surface and secure it against movement or wrinkling.

02

Apply the formulation

Dispense sufficient formulation in front of the coating bar across the required working width.

03

Draw and clean

Move the rod continuously at a controlled speed, then clean the formed surface immediately after use before residual material dries.

Drawdown speed Coating behaviour can be sensitive to drawdown speed. Maintain a consistent speed across samples intended for comparison. Stopping mid-stroke can produce a visible line or local thickness discontinuity.
Nominal wet-film configuration and actual coating thickness The selected rod value represents its nominal wet-film coating configuration and should not be interpreted as a guaranteed deposited wet- or dry-film thickness. Actual thickness depends on formulation rheology, solids content, coating speed, contact conditions, substrate properties and subsequent drying. Where quantitative thickness control is required, calibrate the selected rod against the measured coating obtained with the actual formulation and process conditions.
Surface levelling, cleaning and rod condition The formed metering profile can leave a fine surface pattern immediately after drawdown, whose subsequent levelling depends on the formulation. Viscous or highly loaded materials may retain more texture than fluid formulations. Keep the coating profile clean and free from dried material or mechanical damage. Residue within the metering grooves can alter subsequent coating behaviour, while mechanical damage to the formed profile may affect performance and require replacement of the rod. Clean promptly after use with a solvent compatible with the formulation and stainless steel, then refit the protective caps for storage.

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