Physical Vapor Deposition (PVD)

Physical Vapor Deposition deposits ultra-thin, hard, wear-resistant coatings in vacuum, ideal when you need tight dimensions, long life, and premium cosmetic finishes.

Overview

Physical Vapor Deposition (PVD) is a vacuum coating process that deposits extremely thin, dense films of metals, nitrides, carbides, and oxides onto finished parts. Typical thickness ranges from 1–5 µm, so you can dramatically improve wear resistance, hardness, lubricity, and appearance without meaningfully changing part dimensions or tolerances.

Use PVD when your part already meets its dimensional specs and you need a hard, durable surface or a premium decorative finish. It excels on high-value parts like cutting tools, medical components, and visible hardware where coating performance justifies higher per-part cost. Tradeoffs: part size is limited by chamber capacity, line-of-sight coverage can leave very deep recesses thinly coated, and process temperatures (often 150–500°C) may restrict soft substrates or sensitive assemblies. PVD usually suits small to medium parts, from prototype to production, where surface performance and aesthetics matter more than lowest cost per square inch.

Common Materials

  • Tool steel
  • Stainless steel 17-4
  • Stainless steel 316
  • Carbide
  • Titanium
  • Aluminum 6061

Tolerances

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Applications

  • Carbide and HSS cutting tools
  • Injection mold cavities and cores
  • Medical implants and surgical instruments
  • Firearm slides and barrels
  • Decorative door and cabinet hardware
  • Automotive valve train and engine components

When to Choose Physical Vapor Deposition (PVD)

Choose PVD when you need a very hard, wear-resistant, or decorative surface without significantly changing part dimensions. It’s ideal for finished, high-value parts where surface performance, corrosion resistance, and appearance justify a premium coating. Best for small to medium parts that can tolerate moderate process temperatures and have critical fits or sharp details you do not want to build up with thick coatings.

vs Anodizing

Pick PVD when you need high hardness, low friction, or specific metallic colors on steels, carbides, or titanium, and cannot tolerate the thickness and dimensional growth of anodizing. PVD is also better when you need uniform performance on intricate tooling features and sharp edges that must stay within tight tolerances.

vs Powder Coating

Choose PVD instead of powder coating when you need microns of thickness, not tens of microns, and must preserve precision fits, threads, and fine features. PVD makes more sense for wear-critical or decorative metal parts where coating toughness, hardness, and a crisp, metallic appearance matter more than chip resistance on large structural components.

vs E-Coating

Use PVD over e-coating when the priority is surface hardness, wear resistance, or premium metallic finishes rather than bulk corrosion protection on large assemblies. PVD is better for small, high-value parts where dimensional change must be minimal and coating performance per square millimeter matters more than low cost per square foot.

vs Chromium Electroplating

Select PVD instead of hard chrome when you want similar or better wear resistance with much thinner, more uniform coatings and fewer environmental concerns. PVD is especially attractive for precision tools and components where chrome’s thickness and edge build-up would distort critical dimensions.

vs Nickel Electroplating

Choose PVD over nickel plating when you need ultra-thin functional coatings with high hardness and controlled friction rather than thicker, more leveled deposits. PVD suits tight-tolerance parts and cutting edges where any significant thickness, burr rounding, or dimension shift from plating is unacceptable.

Design Considerations

  • Specify required coating type and thickness range (e.g., TiN 2–4 µm) and which surfaces are critical for coverage or must be masked
  • Call out base material, heat treatment, and surface hardness so the coater can confirm compatibility with process temperatures and adhesion requirements
  • Define maximum allowable dimensional change on fits, threads, and sealing surfaces; avoid relying on PVD to build up worn or undersized areas
  • Target a smooth pre-coat surface finish (often ≤ Ra 0.2–0.4 µm) since PVD films replicate, not hide, underlying roughness or machining marks
  • Avoid deep blind holes and narrow undercuts where line-of-sight coating is poor, or clearly mark them as non-critical for coating
  • Provide robust fixturing or clear fixturing constraints so parts can be oriented for consistent coating thickness on functional surfaces