Metallizing Multiple Materials: The Challenges of Processing Different Substrates in Vacuum

Presented by Robert Malay, PhD, VDI

The challenge of successfully processing a given substrate can often be compounded when that process takes place in a vacuum. Common hurdles to processing materials Roll-to-Roll are present, such as tension control and the elimination of physical defects such as pimples and wrinkles. However, vacuum processes introduce a host of other challenges, such as the evolution of volatiles and reintroduction of atmosphere into a wound roll. These challenges change with various substrates as well, with polymer films processing much differently than fabrics and non-wovens, which in turn differ greatly from metal foils. This paper will go over some of the common challenges and problems that can be prevalent in vacuum processing, and will discuss the differences in requirements for different types of materials, such as polymer films, foils, fabrics, and beyond.