Developments in technology across various industries are pushing the limits of traditional coating methods, with bottlenecks becoming more impactful as performance requirements increase. From EVs to aerospace and beyond, manufacturers are increasingly looking to emerging technologies to avoid these limitations.

In this blog post we explore three emerging coating technologies, with a focus on what decision-makers should understand about each when evaluating their potential usage.

Here’s what we’ll cover:

  • High-power Impulse Magnetron Sputtering (HiPIMS)
  • Hybrid PVD/CVD systems
  • Adaptive process controls & smart coating systems
  • Challenges slowing adoption

High-Power Impulse Magnetron Sputtering (HiPIMS)

HiPims is a pulsed, high-power plasma sputtering technique that generates high ionization (>70%), improving coating density and adhesion.

Key Advantages of HiPIMS

HiPIMS has lower deposition rates versus conventional coating methods, which can become a bottleneck of its own. The cost and complexity of the required equipment is high, too, meaning it is not a simple process to switch.

Use Cases

Applications well suited to HiPIMS are those where coating performance is non-negotiable, and include:

  • Cutting tools
  • Aerospace components
  • Semiconductor thin films

Hybrid PVD/CVD Systems

Hybrid PVD/CVD systems combine two or more deposition methods as a way to balance the trade-offs of each.

Why Hybridisation Matters

Hybrid systems deliver the benefits of constituent processes. For example:

  • PVD delivers surface quality and precision but offers limited thickness and struggles coating into tight corners
  • CVD can create a thicker coat and coat everywhere but leaves a rougher surface finish
  • Hybridising gives precision coating with thickness and full coverage

This approach enables better performance by increasing flexibility, rather than relying solely on better equipment.

Key Benefits

Hybridising PVD/CVD offers a handful of benefits:

  • Reduced residual stress
  • Extended tool life
  • Flexibility to tailor coatings to performance requirements
  • Scalable to production environments once process is established 

Real-World Applications

An article in Science Direct explores how PVD/CVD was used to deposit environmental barrier coatings in next-gen aircraft coatings, showcasing how the precision and low-stress benefits of PVD combine with the thickness and conformed coverage of CVD where either individually would be limiting.

Adaptive Process Controls & Smart Coating Systems

Modern coating technology uses real-time feedback loops to adjust deposition parameters during the process rather than relying on fixed recipes that may be prone to error. This can include AI observation and analysis and sensor arrays, both of which have significant implications on the consistency of the coating, along with reduced material waste and fewer failed runs.

Key Advantages

There are many advantages to adaptive process controls, including: 

  • HIgher coating consistency
  • Real-time optimisation of parameters
  • Reduced variability
  • Improved yield
  • Shorted R&D cycles
  • Less material waste
  • Fewer failed runs
  • Faster design iteration

Limitations

These systems are more sophisticated than their older counterparts, meaning higher levels of operational complexity. The skill requirement of the teams installing and using the machines is higher, with new skills potentially required.

Challenges Slowing Adoption

As with any evolving technology, there are practical barriers to adoption. Here we briefly explore some of the factors determining whether an organisation would want (or be able to) adopt the technologies discussed. 

  • Higher capital investment: the technologies covered here are not incremental upgrades to existing tech, but rather represent significant investment initially and potentially on an ongoing basis, which may be limiting to businesses.
  • Specialist knowledge in short supply: the financial investment is accompanied by skill requirements, not all of which are in plentiful supply. Sourcing and retaining the right staff alongside adoption of new technology makes the picture more complex.
  • Retrofitting is challenging: integrating new technology into established manufacturing lines and processes can present a significant challenge. 

The question with such barriers is when they will be overcome, rather than how. As skills percolate out through the workforce, and as the price of these new technologies falls, they will become more attainable to businesses that currently consider them beyond their reach.

Choosing the Right Technology

To summarise: 

  • HiPIMS is a good fit where coating performance is the non-negotiable
  • Hybrid PVD/CVD is a good fit when balance and scalability matter most
  • Adaptive controls are best for consistency, yield, and future-proofing 

The question when assessing – and adopting – these technologies is simple: which fits your operational needs best? Weigh that against budget, internal skillset and timeline, and the most appropriate path forward should be clearer.

If you’d like to talk more about how these technological developments map onto your processes, get in touch with our team. We’ll be more than happy to discuss.