Vacuum metallization—also known as physical vapor deposition (PVD)—is a vacuum process where a metal vapor condenses onto a substrate surface, forming a thin, bonded coating for EMI shielding, decorative or functional finishes.

In PVD, a solid metal source is vaporized in a vacuum (via evaporation, sputtering or arc), travels through the chamber, then condenses onto the part surface atom by atom to form a thin film.

PVD coatings can be applied to plastics, metals, ceramics and glass—using materials such as aluminum, titanium, alloys, nitrides or carbides—to provide wear resistance, EMI shielding, corrosion protection, or decorative finishes.

PVD coatings are typically harder, more corrosion‑resistant, and thinner than electroplating, operate at lower temperatures, offer precise thickness control, environmental benefits, and maintain dimensional tolerances.

Typical vacuum metallization (PVD) coatings range from about 0.05 µm to a few microns thick, depending on the application—thin decorative films may be <0.1 µm, while EMI or protective finishes often use 1–2 µm layers.