Highly Controlled Parylene C Coating on Titanium for Invasive Biomedical Applications

The rapid development of implantable medical electronics requires robust biocompatible coatings capable of ensuring long-term stability in aggressive physiological environments. Although Grade 1 titanium is widely used for its excellent mechanical properties and corrosion resistance, active implants require defect-free insulating coatings to prevent electrical leakage and metal ion release. This study presents a systematic evaluation of Parylene C (P-C) thin films deposited by the Gorham chemical vapor deposition (CVD) process onto implant-grade titanium substrates. Four coating thicknesses (1, 5, 10, and 20 µm) were deposited and characterized using complementary chemical, morphological, optical, and mechanical techniques. Contact-angle measurements confirmed uniform hydrophobicity (90.56 ± 1.86°), while FTIR and EDX verified the characteristic chemical composition of P-C. Reflectometry, ellipsometry, and interferometry demonstrated excellent thickness control and deposition reproducibility. Pull-off testing showed high initial mechanical integrity, with detachment forces ranging from 52 to 73 N. However, accelerated PBS ageing (21 days at 90 °C) induced significant degradation, particularly for thicker coatings, reducing pull-off forces to 19–42 N. Likewise, thermal-shock cycling (−80 °C to +220 °C) caused severe interfacial damage, decreasing the required detachment force to approximately 5.5 N for 20 µm coatings because of extensive cracking and delamination. These results demonstrate that Parylene C provides excellent conformal coverage and chemical stability on titanium but that its durability is significantly affected by prolonged hydrothermal ageing and extreme thermal loading. This study provides practical guidelines for the design of reliable encapsulation systems for active implantable medical devices and highlights the need for improved interfacial engineering through optimized adhesion-promoting layers or hybrid protective architectures.