PVD for decorative applications Lesson 1: Fundamentals of PVD
Welcome to the Ionbond Summer School! In a few short lessons, we will be teaching you the fundamentals of physical vapor deposition (PVD) for decorative applications.
This lesson, we’ll start off with the basics of the technology. Stay tuned for future lessons on specific PVD technologies, color ranges, and considerations when choosing a PVD coating
Why PVD is the go-to technology for decorative coatings
For applications that need decorative coatings, PVD has become the technology of choice. PVD processes are flexible in process parameters and can create many different finely tuned, coatings. What makes PVD so broadly useful is that the processes generally take place at temperatures between 100 °C and 600 °C. It is even possible to maintain temperatures below 100 °C to coat highly temperature sensitive substrates like plastics.
Each PVD process has its own specialty applications. For decorative coatings, cathodic arc evaporation (CAE) and magnetron sputtering (MS) are the most common. We’ll address both in more detail in the following lessons. For now, let’s discuss the fundamentals of the PVD process.
Figure: Working principle of a PVD process.
Three steps from base material to coating
PVD is a group of plasma processes in which solid material is transferred to the gas or vapor phase and then condenses on the surface of a substrate to form a thin film coating. Generally, all PVD processes can be divided into three phases:
1. Vaporization phase
The base material for the coating is converted from solid state into the gas/plasma phase by introducing energy. In the plasma, the interaction between neutral particles, positively charged particles (ions) and negative charged particles (electrons) plays a crucial role for the PVD process.…
Later, we will describe the main procedures for the vaporization process, which are different in CAE and MS.
2. Transport phase
During the transport phase, the particles in the vapor/plasma phase (which may be neutral or charged) move through the coating chamber. These particles include atoms, ions, atom clusters and, depending on the process, droplets.…
A key aspect of PVD coating is the pressure in the vacuum chamber, which has a significant influence on the transport phase. It must be low enough (usually p = 5E-5 mbar) that there is only very little contamination of foreign atoms in the growing layer. During transport, the particles that move through the system can also react with additional gases such as nitrogen, oxygen or acetylene to enable the formation of metallic or ceramic compounds.
3. Deposition phase
When the particles hit a solid surface, they either bounce off it or they transfer sufficient energy to the surface to become loosely bound as so-called adatoms. When further impinging atoms accumulate, they form nuclei. As the process continues, the nuclei grow together to form islands and ultimately create a more or less cohesive layer.…
The resulting coatings can range in thickness from a few nm to several μm. If the process generates charged particles, the coating formation can be further influenced by applying a so-called bias voltage, which accelerates the particles and helps generate harder, denser layers.
Your PVD foundation is set - let’s explore CAE next
These are the fundamentals of PVD coating. Now you understand vaporization, transport and build-up, stay tuned for the next lesson on cathodic arc evaporation.
Wondering in the meantime if PVD coatings are the right solution also for your decorative application? Contact our experts, which will be happy to discuss your challenges!
Ionbond Summer School
Discover all our lessons on the fundamentals of PVD for decorative applications
PVD for decorative applications Lesson 1: Fundamentals of PVD
Available on 7. August 2025
Begin your Ionbond Summer School journey with the essentials of Physical Vapor Deposition (PVD). This lesson introduces the core phases: vaporization, transport, and deposition, that form the basis of decorative coatings, even on sensitive materials like plastics.
PVD for decorative applications Lesson 2: The cathodic arc evaporation PVD process
Available on 14. August 2025
Learn in lesson two how cathodic arc evaporation (CAE) works, why it’s the most energetic PVD process, and how it enables durable and decorative coatings.
PVD for decorative applications Lesson 3: The magnetron sputtering PVD process
Available on 21. August 2025
In Lesson 3, you'll explore magnetron sputtering: how it works, how it differs from CAE, and why it's ideal for smooth, high-quality PVD coatings.
PVD for decorative applications Lesson 4: Coating color range in decorative PVD
Available on 28. August 2025
This fourth lesson introduces hybrid PVD approaches using CAE and MS, showing how combining technologies enables decorative coatings with unique colors, durability, and performance. Discover Ionbond’s Coating Guide as a practical tool for selecting the right solution.
Questions?
Discuss your challenges with Ron Dielis
Ron Dielis, Global Segment Manager Deco/Sports/Luxury, will be glad to support you.
We will get back to you as soon as possible
Ron Dielis
Global Segment Manager Deco/Sports/Luxury
Ron Dielis
Global Segment Manager Deco/Sports/Luxury