Physical Vapor Deposition (PVD)

PVD applies thin, hard vacuum-deposited films (often TiN/CrN/DLC) for wear resistance and low friction with minimal dimensional change.

Overview

Physical Vapor Deposition (PVD) is a vacuum coating process that evaporates or sputters a solid target and condenses it onto the part as a dense, hard thin film. Common coatings include TiN, TiCN, CrN, AlTiN, and DLC; typical thickness is a few microns, so parts retain fit and geometry while gaining higher surface hardness, lower friction, and improved wear/galling resistance.

Choose PVD for metal components that see sliding contact, abrasive wear, or cosmetic “metallic” finishes and need tight dimensional control. It’s common on cutting tools, molds, and hardware where a thick paint-like coating would interfere with tolerances.

Tradeoffs: PVD is line-of-sight, so deep recesses and shadowed features coat thinner. Surface finish and cleanliness drive results—PVD won’t hide machining marks and will replicate the underlying texture. Coating selection and substrate hardness matter for adhesion; masking adds cost and lead time.

Common Materials

  • H13 tool steel
  • D2 tool steel
  • 440C stainless steel
  • 304 stainless steel
  • Titanium Grade 5
  • Carbide

Tolerances

Coating thickness typically 1–5 µm (0.00004–0.00020 in) per surface; masking and fixturing drive local variation

Applications

  • End mills and drills
  • Injection mold cores and cavities
  • Forming dies and punches
  • Valve stems and seats
  • Firearm and knife components
  • Medical instrument jaws and cutters

When to Choose Physical Vapor Deposition (PVD)

Choose PVD when you need a hard, wear-resistant, low-friction surface with minimal dimensional change, especially on precision metal parts. It fits low to medium volumes where per-part value is high and post-coat grinding or lapping is undesirable. Best results come from clean, well-finished surfaces and geometries that allow line-of-sight deposition.

vs Anodizing

Choose PVD when the part is steel, titanium, or carbide, or when you need very high surface hardness and low friction without changing part size. PVD also offers specific functional films (TiN/CrN/DLC) that target wear and galling in sliding contact.

vs Powder Coating

Choose PVD when tight fits, threads, or sealing surfaces can’t tolerate a thick organic coating. PVD keeps edges crisp and adds wear resistance; powder coating is better suited for corrosion protection and cosmetic coverage on larger, less tolerance-sensitive parts.

vs E-Coating

Choose PVD when the goal is wear resistance, hardness, or reduced friction on contact surfaces rather than uniform corrosion paint coverage. E-coat coats complex cavities more uniformly, while PVD performs best on accessible surfaces where line-of-sight deposition is acceptable.

vs Chromium Electroplating

Choose PVD when you want a hard coating with excellent thickness control in the micron range and you need to preserve sharp features and tight dimensions. PVD avoids thick buildup and is often preferred for tooling surfaces where minimal post-finish is required.

vs Nickel Electroplating

Choose PVD when wear, galling, and friction dominate and you don’t want to rely on a thicker metallic deposit to build up size. Nickel plating is commonly used for corrosion protection or dimensional build; PVD is typically a functional topcoat with minimal thickness.

Design Considerations

  • Specify functional surfaces and mask lines clearly (threads, sealing lands, bearing fits) to avoid surprise buildup or uncoated areas
  • Avoid deep blind pockets and narrow slots when uniform coating is critical; design for line-of-sight access or accept thinner coverage
  • Call out required coating type and performance target (e.g., TiN for wear, DLC for low friction) rather than only a color
  • Control base material hardness and heat treat before coating; post-coat machining usually removes the film
  • Set a surface finish requirement on coated faces; PVD mirrors the substrate and won’t hide tool marks
  • Provide racking/fixturing constraints (no witness marks on cosmetic faces, allowable contact points) to speed quoting and reduce scrap