Anas Ghailane^1,2, Rajesh Ganesan², Lucca Pernagidis¹, Christos Pernagidis^1
1Avaluxe Coating Technologies, Fürth, Germany
²The University of Sydney, Sydney, Australia
In this study, we present our investigation into hybrid High Power Impulse Magnetron Sputtering (HiPIMS) systems—combined with DC magnetron sputtering and cathodic arc discharge—as a transformative platform for producing exotic, high-performance coatings with tailored aesthetic and mechanical properties. HiPIMS represents a significant advancement over conventional DC magnetron sputtering by delivering a highly ionised, energetic plasma, which enhances coating density, adhesion, and microstructural control. We employed this capability to deposit protective and decorative coatings on various substrates, including challenging materials like polymers. To expand these coatings' functional and visual capabilities, we developed and optimised hybrid configurations. The HiPIMS–DC sputtering system merges the dense, smooth coating benefits of HiPIMS with the high deposition efficiency of DC sputtering, enabling tuneable optical properties and vibrant colour finishes. Reactive sputtering of materials such as TiN and TiCN allowed us to achieve gold, rose gold, and other visually compelling hues through controlled stoichiometry and interference effects.
Further, we explored a hybrid HiPIMS + cathodic arc (ARC) system, combining pulsed arc evaporation with HiPIMS pulses. While cathodic arc offers excellent adhesion and high metal ion yield, it is typically hindered by macroparticle generation. Through hybridization, we reduced surface defects and preserved high ion flux, allowing us to produce coatings with deeper blacks, anthracite tones, and ultra-smooth textures. These colour effects, previously dominated by arc-based processes, were replicated and enhanced under the HiPIMS hybrid scheme, offering new design freedom in decorative and functional applications.
Our findings demonstrate that hybrid HiPIMS systems unlock new possibilities for aesthetic coatings with superior adhesion, hardness, and colour uniformity. The potential to deposit a wide range of materials—including nitrides, carbonitrides, and oxides—with controlled layer thickness and microstructure supports both visual customization and long-term durability. These results are particularly relevant for automotive, tooling, electronics, and luxury goods industries where surface performance and appearance are equally critical.
This work not only validates hybrid HiPIMS as a flexible, scalable platform for advanced PVD coatings, but also underscores its emerging role in bridging material functionality with visual design.