PVD Process Overview: Mastering Surface Finishing with Physical Vapor Deposition | JLY Precision Tech China

Get a detailed overview of the PVD process and how it revolutionizes surface finishing. JLY Precision Tech, a leading PVD coating provider in China, explains the steps, benefits, and applications with 2024 data and case studies.

July 21, 2025

PVD Process Overview: A Comprehensive Guide to Surface Finishing with Physical Vapor Deposition

1. Introduction to the PVD Process

The PVD process involves depositing thin films of material onto a substrate in a vacuum environment. These films are typically only a few nanometers to micrometers thick but offer significant improvements in hardness, wear resistance, and chemical stability compared to traditional coatings. PVD coatings are used in a wide range of industries, from aerospace and automotive to medical devices and consumer electronics.

Attribute	PVD Coating	Electroplated Ni	Spray Paint
Thickness	5 nm–5 µm	5–50 µm	25–100 µm
Hardness (HV)	2 500–3 500	700	200
Max Temp (air)	1 000 °C	300 °C	150 °C
REACH Status	Compliant	Restricted	Limited
Uniformity	±5 nm	±10 µm	±25 µm

2. Detailed Steps of the PVD Process

The PVD process consists of several key steps, each meticulously controlled to ensure the highest quality finish:

Step	Vacuum Level	Temperature	Action
Pre-clean	10⁻³ mbar	25 °C	Plasma etching removes contaminants
Bond Layer	10⁻³ mbar	200 °C	50 nm Cr or TiN for adhesion
Deposition	10⁻⁴ mbar	150–500 °C	Vapor atoms condense to form film
Post-polish	Air	25 °C	CMP or ion-beam finishing to Ra ≤ 0.01 µm

3. PVD vs Traditional Surface Treatments – 2024 Comparison

Method	Thickness (µm)	Hardness (HV)	Salt-Spray (h)	Max Temp (°C)	Typical Use
Electroplated Ni	25	700	48	300	Decorative trim
Spray Paint	50	200	48	150	Body panels
Traditional DLC	2	2 000	500	400	Cutting tools
HiPIMS TiAlCrN	2	2 900	1 200	1 000	Turbine blades
Filtered Arc ta-C	0.5	3 000	1 000	400	Medical drills
Reactive CrAlON	1	2 400	800	600	EV motor punches

4. Real-World Applications and Case Studies

Case 1 – EV Motor Punch

Client: US EV Tier-1
Challenge: 0.35 mm electrical steel sticking at 400 °C
Solution: 1.8 µm CrAlON + 50 nm a-C:H
Result: Tool life 4× longer, scrap −40 %

Case 2 – Medical Staple

Client: US MedTech startup
Challenge: Low-friction 316L piercing
Solution: 300 nm ta-C + 30 nm Cr adhesion
Result: Penetration force −25 %, CE mark granted

Case 3 – Smartphone EMI Shield

Client: Global mobile OEM
Challenge: 6 GHz EMI leakage in SiC inverter
Solution: 150 nm Ag/Ni/Cr multilayer
Result: Shielding 85 dB @ 6 GHz, CISPR 25 passed

5. Step-by-Step PVD Workflow

Stage	Actions	KPIs	Lead Time
1	Design Review	CAD + CFD + DOE	24 h
2	Prototype	1–10 pcs	48 h
3	Validation	CT, CMM, salt-spray	5 days
4	Scale-Up	SPC, poka-yoke	2 days
5	Production	24/7 lights-out	7–10 days
6	QA	Calot, CpK ≥1.67	12 h