Characteristics and electrochemical properties of Al₂O₃ thin films on surgical scalpel blades

Purpose: Surface modification techniques play an important role in shaping the physicochemical properties of surgical tools. The article discusses the problem of the destruction of surgical scalpel blades and the methods of depositing thin films on them. Design/methodology/approach: Aluminium oxide thin films were deposited on the surface of surgical scalpels by atomic layer deposition (ALD) with a different number of cycles. The corrosion resistance of the blades with and without coatings was tested. The thickness of the deposited thin films was examined, and electrochemical tests were performed. Findings: The ALD method allows the uniform deposition of the Al₂O₃ thin films on surfaces with complex shapes like a surgical scalpel. Each process cycle increases the layer by a specific value of about 0.1 nm. It is possible to control the thickness of the thin film precisely, which was confirmed by testing the thickness of the coatings with a reflectometer. Electrochemical tests have confirmed that ALD thin films are highly resistant to corrosion, which is extremely important in medical devices. The relationship between the thickness of the coating and its corrosion resistance was determined. Research limitations/implications: The research conducted is the basis for further research on increasing the corrosion resistance of scalpel blades. In the next stages, multi-component layers, such as AZO, will be deposited on the scalpel blades, which could increase corrosion resistance. Practical implications: During a surgical procedure involving cutting living tissue, a worn and unsharp tool is replaced with a new one, even several times. It generates a lot of medical waste. To minimise the amount of medical waste, it is proposed to use ceramic layers on the blades, thanks to which they will be resistant to corrosion for longer and thus remain sharp longer. Originality/value: The PVD and CVD methods have been the most frequently reported. Still, the ALD method is characterised by high accuracy in controlling the thickness of layers and enables all elements to be covered, even in complex shapes. However, no reports of its use on scalpel blades have been identified.