Whether it's a high-precision mold on the factory floor or a jet engine at 30,000 feet, when a critical component fails, the problem usually starts on the surface. The substrate must be able to tolerate heat, friction, and corrosion in that thin outer layer where it meets the environment. If that layer fails, the system could collapse.
Advanced coatings like physical vapor deposition (PVD) and diamond-like carbon (DLC) can help with that. Although these incredibly thin layers are not visible to the naked eye, they significantly improve resistance to high temperatures and reduce wear and friction. PVD and DLC coatings help ensure that high-performance equipment operates more smoothly and for a longer amount of time, from race cars and aerospace components to medical tools and energy systems.
In our coatings lab, Calico’s engineers solve practical issues using a science-based methodology. We tailor each coating to the unique requirements of each job thanks to our in-depth materials knowledge, cutting-edge machinery, and cross-industry experience. We have the science and tools to safeguard what matters, whether you're dealing with extreme heat, harsh chemicals, or continuous motion.
Our engineers are engaged in behind-the-scenes problem-solving long before any coating is applied. "Every project begins with questions: What material is this part made of?" says Calico’s lead process engineer. “What kind of setting will it be in? What precisely is the client attempting to resolve?” Ensuring a coating will perform under pressure, heat, and wear is more important than simply choosing one.
Coatings react differently to different metals and alloys—some bond well while others do not. While some materials can tolerate high temperatures involved during deposition, others cannot. A coating will fail to perform if it adheres poorly or degrades under stress. For dependable, long-lasting results, it is essential to understand the interaction between the base material and the coating. This is where our process engineers—and their knowledge of materials science—plays a vital role.
We put our coatings through a wide range of tests to ensure they function as intended. We test for adhesion using scratch tests, corrosion resistance using salt spray chambers, friction using tribometers, and hardness using nanoindentation. All testing is done in advance to ensure that, by the time a coated part leaves our lab, it’s ready to take on whatever challenges the real world may present.
Diamond-like carbon (DLC) coatings have a wide range of real-world applications across industries. This unique type of carbon combines graphite-like and diamond-like bonds. The result? A coating that is chemically stable, exceptionally slick, and impressively durable. There are several DLC variants, such as hydrogenated (a-C: H), tetrahedral (ta-C), and doped DLC, each with slightly different hardness and deposition characteristics.
DLC offers a remarkably low coefficient of friction—as low as 0.05—providing excellent wear resistance without the need for lubrication. They are also extremely hard, with values reaching up to 4,500 on the Vickers hardness scale. Additionally, DLC is biocompatible, meaning it is nontoxic to humans, and remains stable when exposed to most chemicals.
The smooth surface of DLC is a major factor in engineers' decisions. For instance, a rough coating may cause increased drag or premature wear in a high-performance racing gearbox. The glassy finish of DLC keeps things cooler for longer by lowering heat and friction. It is a workhorse that produces results, despite its lack of flash.
In advanced manufacturing, PVD is the go-to solution for harsh environments. In a nutshell, PVD is a vacuum-based process that applies metals like titanium, aluminum, or chromium to parts as incredibly thin coatings that are usually only a few microns thick. These coatings are often nitrides, carbides, or oxides and can be customized for any task. Deposition temperatures for PVD processes typically range from ~200°C to 500°C, so substrate heat tolerance is an important factor in selection.
One of PVD's biggest advantages is flexibility. Hardness can be fine-tuned by stacking nanolayers, while combining different materials can enhance both corrosion resistance and thermal stability. Whether it's titanium nitride (TiN) for a gold-colored tool coating or aluminum titanium nitride (AlTiN) for high-temperature applications, the process can be customized to tailored to meet highly specific performance requirements.
Furthermore, the application technique affects the surface texture of PVD coatings. For functional surfaces, sputtering creates a smoother surface. However, when more grip or aesthetics are required, arc deposition creates a slightly rougher texture, offering improved grip or a distinct visual appearance, depending on the application.
PVD is a precision tool in the coating world. It’s not one-size-fits-all—it’s more like a custom-built armor that protects parts where failure just isn’t an option.
The process of selecting between DLC and PVD is supported by science and begins with the part itself. What kind of material is the base? How hot will it get? Will it encounter friction, pressure, chemicals, or all three? Does it have to be grippy, smooth, or a combination of both?
As our lead process engineer said, “It’s not just about applying a coating—it’s about understanding the chemistry beneath it. ”Some materials bond better with specific coatings than others, and certain substrates may have limited heat tolerance during deposition. That is why every project starts with a deep dive into the application and substrate.
In many cases, the best results come from layering or combining technologies:
PVD and DLC coatings are not merely laboratory experiments; they are being used to solve real-world issues in significant industries. Here's a brief look at the industries and reasons these coatings are effective:
No matter the challenge—wear, friction, heat, or corrosion—DLC and PVD coatings are doing the hard work behind the scenes, keeping critical parts running longer and stronger.
You might not see them, but coatings like DLC and PVD are doing some of the hardest work in modern industry. They are the silent protectors—keeping engines running, tools sharp, turbines spinning, and surgical instruments clean. They are extremely thin yet highly effective, but they make a massive difference in uptime, safety, and overall performance.
When applied correctly, these coatings do not just extend part life—they boost efficiency, cut maintenance costs, and help prevent unexpected breakdowns. It all comes down to understanding the materials and engineering from the nano scale up.
As our lead process engineer put it, “Nano-scale knowledge and materials expertise drive our ability to solve real-world wear and friction problems.” That mindset—combining science, experience, and strategic problem-solving—is what sets our effective coating solutions apart.
If you are facing a challenge with wear, corrosion, or performance loss, don’t guess. Work with Calico’s process engineers who understand the science behind the surface. The right coating might be exactly what your component—and your bottom line—needs.
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