Frequently Asked Questions – AGC Plasma Technology Solutions

Summary of Content:

What is the History and Background of AGC Plasma Technology Solutions?

AGC Plasma’s PVD and PECVD equipment offers a unique combination of performance, flexibility, and deep application know-how that sets them apart from other vacuum equipment suppliers.

One of AGC Plasma’s key differentiators is our decades-long experience using PVD and PECVD equipment in the actual production of low-emissivity (Low-E) glazing. This background gives our team unparalleled insight into the real-world challenges of thin film coating processes — not just from an equipment perspective, but also from a product development, manufacturing and maintenance standpoint.

This application-driven expertise translates into:

  • Faster production ramp-up: Our team supports customers hands-on during start-up phases to reduce trial-and-error and speed up time to market.
  • Lower cost of ownership: Thanks to proven process recipes and equipment tuning strategies that are grounded in industrial practice.
  • Support for product innovation: We assist in developing new thin film products, offering concept validation and prototyping.

In addition, our demonstration center in Lauenförde, Germany, is equipped with several pilot lines that allow customers to:

  • Test new materials and layer stacks
  • Validate coating performance
  • Accelerate proof-of-concept realization

Combined with a modular equipment platform and global service network, AGC Plasma delivers the flexibility and process reliability that high-tech manufacturers demand — whether for glass, polymer film, metal coil or textiles and non-wovens.

How does AGC Plasma support customers from R&D to industrial-scale production?

AGC Plasma provides end-to-end support throughout the entire coating process lifecycle, from concept to commercial-scale production:

  • Consultation: Understand your materials, performance goals, and production needs
  • Process development: Leverage our lab-scale equipment and expertise to develop and optimize coatings
  • Prototyping and scale-up: Move from R&D to pilot production with our modular platforms
  • Industrial deployment: Design and deliver fully customized turnkey systems for large-scale manufacturing
  • After-sales support: Ongoing service, upgrades, and process tuning

This integrated approach ensures fast time-to-market and reduced risk for customers looking to innovate with advanced coatings.

Does AGC Plasma support students and startups?

Yes, AGC Plasma actively supports students and startups by offering traineeships, technical mentorship, and access to pilot coating equipment at our demonstration center. We believe that empowering young innovators helps drive progress in thin film technologies and advanced manufacturing.

Students and early-stage companies can benefit from:

  • Hands-on training with industrial PVD and PECVD systems
  • Use of roll-to-roll pilot lines for research, testing, and prototyping
  • Guidance from experienced engineers in vacuum coating and process development

At AGC Plasma, we’re proud to contribute to academic and entrepreneurial R&D. By making our expertise and facilities available, we help promising projects move from concept to proof of feasibility—accelerating innovation in areas such as sustainable coatings, medical membranes, and advanced materials.

Our commitment to nurturing talent is part of our broader mission to create positive impact through technology and collaboration.

What is the expected lifetime of vacuum coating equipment and does AGC Plasma refurbish used equipment?

Vacuum coating equipment, including PVD and PECVD systems, is designed for long-term industrial operation and durability. At AGC, some of our glass coaters have been running continuously 24/7 for over 30 years, demonstrating the exceptional lifespan and robust design of our systems.

To achieve such long equipment life, preventive maintenance is critical. Routine servicing ensures:

  • Consistent thin film coating quality
  • Reduced downtime and repair costs
  • Extended system lifespan
  • Lower total cost of ownership (TCO)

AGC Plasma supports customers through a tailored Service Level Agreement (SLA) that covers:

  • Scheduled preventive maintenance for vacuum coating systems
  • Capacity expansions or system upgrades
  • Refurbishment of used PVD and PECVD equipment using the latest technology

Whether you're running legacy vacuum deposition systems or planning new production lines, AGC Plasma ensures long-term value, performance, and support.

What sustainability advantages do thin film coating technologies offer?

Thin film coating technologies such as PVD (Physical Vapor Deposition) and PECVD (Plasma-Enhanced Chemical Vapor Deposition) offer significant environmental and sustainability benefits compared to traditional wet coating or electroplating methods:

  • No hazardous chemicals or wastewater – Vacuum-based processes are clean and solvent-free, eliminating the use of toxic substances and reducing emissions.
  • Efficient material usage – Nano-scale coatings use minimal raw materials while delivering high-performance surfaces.
  • Lower energy consumption – The volume of the vacuum vessels is minimized and the latest generation of vacuum pumps and power supplies are selected by AGC Plasma for optimized electricity consumption.
  • Supports circular economy – Coated components remain recyclable, and coatings can often be reapplied or upgraded without scrapping the base material.

AGC Plasma’s PVD and PECVD systems help manufacturers reduce their environmental impact while improving product performance, aligning with modern sustainability and ESG targets.

What Types of Turnkey Coating Equipment Does AGC Plasma Offer?

AGC Plasma specializes in designing and manufacturing custom turnkey vacuum coating equipment tailored to our customers' specific production needs. Our systems are built around cutting-edge thin-film deposition technologies and are available in formats suitable for everything from R&D to full-scale industrial production.

Our Core Coating Technologies

Our equipment leverages state-of-the-art deposition methods to achieve superior film quality and performance.

  • Proprietary Magnetron Sputtering and PECVD: Our primary expertise is in magnetron sputtering and Plasma Enhanced Chemical Vapor Deposition (PECVD). We have developed our own high-performance, proprietary deposition sources for these technologies to ensure maximum efficiency, reliability, and coating quality.

  • Integrated Multi-Technology Systems: We are also experts at systems integration. We can incorporate a variety of deposition sources from leading component manufacturers into our coating platforms, including thermal evaporation and ion implantation, to create highly versatile and capable systems.

Equipment Formats for Every Substrate

We provide two main types of industrial coating equipment, designed for different substrate forms:

  • Sheet-to-Sheet Coaters: These systems are engineered for depositing thin films onto planar or slightly curved rigid substrates, such as glass sheets, wafers, or individual components. They are ideal for applications where high precision on individual parts is critical.

  • Roll-to-Roll (R2R) Coaters: Also known as Reel-to-Reel, this equipment is designed for the continuous coating of flexible substrates like polymer films and thin metal coils. R2R technology is essential for the high-throughput manufacturing of flexible electronics, battery components, advanced packaging, and more.

Whether you need a compact system for research and development or a large, fully automated coater for industrial mass production, AGC Plasma can engineer a turnkey solution that meets your specific performance and throughput goals.

Does AGC Plasma supply thin film coating equipment for powder and particles?

While our primary commercial equipment lines focus on Sheet-to-Sheet and Roll-to-Roll systems, AGC Plasma is actively pioneering the future of thin-film coating for powders and particles. We are at the forefront of developing innovative solutions for this challenging but high-potential field.

Our expertise in this area is demonstrated by our significant involvement in the REMADE project, a collaborative initiative focused on upgrading recycled metal powders for use in advanced manufacturing. Within this project, AGC Plasma's key contribution was to develop the concept for a high-volume, industrial powder coater that leverages our deep knowledge of PVD (Physical Vapor Deposition).

To support this innovation, AGC Plasma has access to several pilot coating installations at leading research centers, allowing us to collaborate with partners on proof-of-concept trials and process validation.

While a standardized powder coating system is not yet part of our standard product portfolio, our R&D work and access to pilot facilities place us in a leading position to develop next-generation equipment. We welcome discussions with industrial and research partners who are interested in exploring custom solutions for powder and particle coating applications.

Does AGC Plasma offer other coating deposition technologies, for example thermal evaporation?

Yes, AGC Plasma can integrate a variety of coating deposition technologies from different component manufacturers into our customized vacuum coating systems. This flexibility allows us to tailor solutions to specific production or research requirements.

For example, AGC is currently developing and integrating thermal evaporation systems for materials like lithium metal, supporting next generation battery architectures. Additionally, we incorporate ion implantation sources used for metal coloration and Anti-Reflective treatment of Sapphir in the luxury goods industry, enhancing aesthetic appeal and surface properties.

Our ability to combine multiple technologies—such as PVD, PECVD, thermal evaporation, and ion implantation—provides customers with versatile, integrated vacuum coating systems optimized for their unique application needs.

Does AGC Plasma also offer atmospheric adhesion promotion equipment, like corona treatment? What are the advantages of AGC Plasma’s PVD and PECVD systems compared to these atmospheric plasma technologies?

AGC Plasma does not supply corona treatment equipment, which is typically used exclusively for adhesion promotion on low surface energy materials prior to bonding, printing, or painting.

Instead, AGC Plasma specializes in advanced PVD (Physical Vapor Deposition) and PECVD (Plasma Enhanced Chemical Vapor Deposition) technologies. These systems enable the application of functional nano coatings made from materials such as metals, oxides, nitrides, and carbides.

Compared to corona treatment—which only modifies the surface energy temporarily—AGC’s thin film coatings provide durable, engineered functionality. These coatings can offer:

  • Optical performance (e.g. anti-reflective or low-emissivity properties)
  • Liquid repellency
  • Electrical conductivity or insulation
  • Anti-bacterial and anti-viral functionality
  • Catalytic properties
  • Decorative and wear-resistant finishes

AGC’s PVD and PECVD technologies go far beyond simple adhesion promotion, offering long-lasting solutions tailored to high-performance and industrial applications.

How do magnetron sputtering and Plasma Enhanced Chemical Vapor Deposition (PECVD) work?

Magnetron sputtering and Plasma Enhanced Chemical Vapor Deposition (PECVD) are two powerful vacuum deposition techniques used to create high-performance thin films. While both use plasma, they are fundamentally different processes.

Magnetron Sputtering: A Physical Process

Magnetron sputtering is a highly versatile Physical Vapor Deposition (PVD) method. The process works by physically ejecting atoms from a source material onto a substrate.

  • How it works?

  1. A vacuum chamber is filled with an inert gas (like argon), which is then ionized to create a plasma.

  2. This plasma is used to bombard a "target," which is a solid block made of the desired coating material.

  3. The impact of the ions ejects, or "sputters," atoms from the target.

  4. These sputtered atoms travel through the vacuum chamber and deposit onto the substrate (e.g., glass), forming a thin, uniform film.

  • The Role of Magnets: Powerful magnets are placed behind the target to confine the plasma close to its surface. This dramatically increases the efficiency of the sputtering process, resulting in higher deposition rates.

Plasma Enhanced Chemical Vapor Deposition (PECVD): A Chemical Process

PECVD is a chemical process that grows a thin film on a substrate from a gaseous state. Unlike traditional CVD, which requires very high temperatures, PECVD uses plasma to drive the chemical reaction at much lower temperatures.

  • How it works?

  1. A "precursor" gas, which contains the chemical elements of the desired film, is introduced into the vacuum chamber.

  2. A plasma is generated, providing the necessary energy to break down (decompose) the precursor gas molecules.

  3. These decomposed chemical species then react and bond on the substrate surface, growing into a solid thin film.

What are the main advantages of magnetron sputtering and Plasma Enhanced Chemical Vapor Deposition (PECVD)?

Both Magnetron Sputtering and Plasma Enhanced Chemical Vapor Deposition (PECVD) are thin-film deposition techniques, but they excel in different areas. Choosing the right technology depends on your specific material, substrate, and production requirements.

Advantages of Magnetron Sputtering

Magnetron sputtering is a versatile PVD process renowned for its precision and material flexibility.

  • Material Versatility: It can deposit a vast range of materials, including metals, alloys, oxides, and nitrides, even those with very high melting points. This makes it ideal for creating complex multi-layer coating stacks in a single pass through the coater.

  • Superior Large-Area Uniformity: It is the industry standard for producing highly uniform coatings over large-area substrates. AGC has pushed this capability even further with our proprietary iOSMB magnet bar technology, which delivers high-precision thickness control on both flat and curved substrates.

  • Advantages of Plasma Enhanced Chemical Vapor Deposition (PECVD)

PECVD is a chemical process valued for its gentle nature, speed, and ability to coat complex shapes.

  • Low-Temperature Processing: The process operates at very low temperatures (around 60°C), making it a good choice for heat-sensitive substrates like polymers and other delicate materials, as it significantly reduces the risk of surface damage.

  • 3D Conformality: PECVD coatings are more conformal compared to magnetron sputtering, meaning they can cover complex 3D topographies. This is because the gaseous precursor effectively navigates surface roughness, minimizing the "shadowing" effects common in line-of-sight PVD processes.

  • High Deposition Rates&Low Stress: It typically achieves higher deposition rates than sputtering. Additionally, the resulting films have significantly lower internal stress, which is critical for the durability of coatings on flexible or delicate substrates.

At a Glance: Magnetron Sputtering vs. PECVD

Feature Magnetron Sputtering PECVD
Temperature Requirements Low to Moderate Low
Film Density High Medium
Material Types Metals, Oxides, Nitrides Insulators, Semiconductors
Deposition Rate Moderate High
Conformality on 3D Structures Moderate Better
Substrate Damage Risk Moderate (energetic atoms) Low (gentler plasma)

In summary, magnetron sputtering is the go-to choice for its material versatility and superior uniformity on large, rigid surfaces. PECVD excels with its gentle, high-speed, and more conformal coating capabilities, especially for heat-sensitive and three-dimensional substrates.

What are the key advantages of AGC's PlasmaMAX™ over conventional PECVD systems?

To overcome the limitations of conventional PECVD, AGC Plasma developed PlasmaMAX™, our patented, linear source PECVD technology designed for high-volume industrial coating.

PlasmaMAX™ revolutionizes the PECVD process through its unique design and superior performance.

  • Advanced Source Design: The technology uses a pair of hollow, elongated electrodes. The process gas (e.g., argon, oxygen) is fed into this cavity and ionized by a mid-frequency power supply (20-100 kHz), creating a very high-density plasma. This plasma then exits uniformly through a series of openings facing the substrate.

  • Separated Injection: Crucially, the precursor gas is introduced separately into the space between the electrodes. This separation of plasma generation and precursor injection is a key innovation.

  • Key Advantages of PlasmaMAX™:

    • Ultra-High Deposition Rate: It achieves exceptionally high coating speeds, making it ideal for industrial mass production.

    • High Efficiency: The design ensures a very high utilization of the precursor gas, reducing waste and operational costs.

    • Contamination-Free Operation: By preventing the precursor from entering the plasma generation cavity, PlasmaMAX™ sources avoid the contamination build-up that plagues conventional systems. This allows for multiple days of non-stop coating campaigns, maximizing uptime and productivity.

    • Hybrid Functionality: PlasmaMAX™ sources can be seamlessly integrated with magnetron sputtering cathodes in the same coater, enabling the creation of novel, multifunctional coatings and advanced surface treatments

What deposition rate can be reached for silicon oxide coating for optical applications with AGC's PlasmaMAX™ PECVD technology?

AGC’s PlasmaMAX™ PECVD technology enables significantly faster silicon oxide (SiO₂) coating compared to traditional PVD methods, aiming to increase production throughput while reducing costs.

In industrial environments, dynamic deposition rates (DDR) from 30 nm·m/min up to over 200 nm·m/min have been demonstrated with excellent film uniformity on substrates up to 3.2 meters wide.

Key precursors used in the SiO₂ PECVD process include silane, TMDSO (tetramethyldisiloxane), and HMDSO (hexamethyldisiloxane), which facilitate high-quality optical coatings suited for applications like architectural glass and display technologies.

What other coating materials have been deposited by AGC's PlasmaMAX™ PECVD technology?

AGC’s PlasmaMAX™ PECVD technology allows for the deposition of a broad range of thin film materials by adjusting precursor chemicals and process gases.

Some of the main materials deposited with PlasmaMAX™ PECVD include:

  • Silicon-based coatings: silicon oxide (SiO₂), silicon nitride (Si₃N₄), silicon oxynitride (SiON)

  • Carbon coatings: Polymer-Like Carbon (PLC),  hydrogenated amorphous carbon (a-C:H), Diamond-Like Carbon (DLC), amorphous carbon
    (a-C) from methane or acetylene precursors.

  • Organosilicon and fluorocarbon coatings: providing hydrophobic and water-repellent surfaces

The ability to tailor coating composition and properties by varying precursor gases—such as silane, TMDSO, HMDSO, fluorinated gases, and nitrogen—makes PlasmaMAX™ PECVD an ideal platform for high-performance, customizable thin films. It is also possible to include dopant into the coatings by pre-mixing precursors.

For more detailed information, you can refer to the official AGC Plasma PlasmaMAX™ PECVD leaflet.

What is the difference between a batch coating system and an inline system?

The fundamental difference between a batch coating system and an inline coating system lies in their operational process flow. A batch system operates in a "stop-and-go" cyclical manner, while an inline system is designed for continuous production. The choice between them depends on factors like production volume, substrate type, and process flexibility.

Batch Coating System

A batch coating system processes substrates in discrete groups, or "batches". The entire process occurs within a single, sealed vacuum chamber.

  • Process Flow: Substrates are loaded onto a fixture (like a carousel or drum), the chamber is sealed, the air is pumped out to create a vacuum, the coating is applied, the chamber is vented back to atmospheric pressure, and finally, the finished substrates are unloaded. This entire cycle is repeated for the next batch.
  • Best Suited For: Batch systems are highly versatile and ideal for R&D, prototyping, coating complex 3D shapes (like domes or curved parts), and low-to-medium volume production runs where process parameters may change frequently.

batch-coating.png

Inline Coating System

An inline coating system functions like a continuous production line. Substrates move via a conveyor system through a series of connected chambers, with the main process chamber remaining constantly under vacuum.

  • Process Flow: Substrates are loaded into an initial chamber (a "load-lock"), which is then pumped down. The substrates are then automatically transferred into the main process chamber(s) for coating, and finally moved into an "unload-lock" chamber which is vented to allow for removal—all while the central coating zone remains at vacuum.

  • Best Suited For: Inline systems are the industry standard for high-volume mass production of standardized substrates, such as flat glass sheets or wafers. They are optimized for high throughput, superior coating uniformity, and automated operation.

 

inline-coating-system.png

Summary Table: Batch vs. Inline Coating

Feature Batch Coating System Inline Coating System
Process Flow Stop-and-Go (Cyclical) Continuous (Linear Flow)
Throughput
 Lower (due to repeated pump/vent cycles) Higher (optimized for continuous operation)
Ideal Use Case R&D, Prototypes, Complex Shapes High-Volume Mass Production

Substrate
Flexibility

Very High (handles diverse
shapes/sizes)

Optimized for standardized shapes (e.g., flat
sheets)

Process
Changeover

Easier (adjust jigs/parameters per
batch)

More involved (optimized for long runs of one
product)

Coating
Uniformity

 Good Superior (ideal for large area precision)

In summary, batch coating systems are ideal for small-scale, flexible production, while inline systems excel in high-throughput, large-scale manufacturing.

What are the advantages of an inline coating system versus a batch system?

At AGC Plasma, we have leveraged decades of experience in high-volume manufacturing to perfect our inline coating systems. Originally developed for depositing complex solar control and low-emissivity (Low-E) coatings on architectural and automotive glass, these systems are continuously optimized to deliver the lowest cost of ownership.

Compared to traditional batch coating systems, the inline approach offers significant advantages in performance, productivity, and scalability.

  • Superior Coating Uniformity and Precision: Our inline architecture provides exceptional control over the deposition process, resulting in highly precise and repeatable film characteristics. We consistently achieve a coating non-uniformity of less than 0.3%, a level of precision that is difficult to match in batch systems.

  • Maximized Throughput and Productivity: Inline systems are designed for continuous operation. By minimizing pump-down times and streamlining the process flow, they enable significantly faster processing cycles and greater overall productivity compared to the start-stop nature of batch coaters.

  • Versatile Substrate Handling: Our inline platforms are engineered with flexibility in mind. They are capable of processing a wide variety of substrate types, including both rigid materials (like glass) and flexible substrates (like polymer films or metal foils), often within the same system architecture.

  • Future-Proof Scalable Architecture: The modular design of our inline coaters is a key strategic advantage. It allows for the easy addition of new process chambers or deposition zones as your production needs grow or your technology evolves. This future-proofs your investment and supports seamless scalability and capacity increases.

What are the main application fields for the large-area sputtering equipment and industrial thin-film coating systems developed by AGC Plasma?

AGC Plasma specializes in advanced thin-film deposition technologies, offering large-area sputtering equipment and industrial thin-film systems for a wide range of applications across industries.

Applications of Large-Area Sputtering Equipment

AGC Plasma’s sputtering systems are designed for high-precision coatings on large substrates, enabling applications such as:

  1. Optical Coatings: Low-emissivity, anti-reflective, and anti-scratch coatings for glass and astronomical telescope mirrors (reflective silver and aluminum).

  2. Textile Metallization: Making textiles conductive and/or heat reflective, including applications in multi-spectral camouflage (e.g., camouflage tents).

  3. Anti-Bacterial and Anti-Viral Coatings: Upscaled during the NanoBloc HORIZON project, AGC Plasma developed oxide matrix coatings with silver doping for antimicrobial and antiviral properties.

  4. Chromate-Free Wear-Resistant Coatings: Environmentally friendly (Cr6+-free) coatings for stainless steel plates.

  5. Corrosion-Resistant Layers: Protective coatings for fuel cell and electrolyzer components.

  6. Lithium Sputtering: Thin-film lithium coatings for lithium metal anode manufacturing.

Applications of Industrial Thin-Film Systems

AGC Plasma’s PlasmaMAX™ thin-film systems are optimized for high-performance coatings, including:

  1. Optical Layers: Deposition of silicon dioxide (SiO₂) and silicon oxynitride (SiON) for optical applications.

  2. Textile Functionalization: PFAS-free hydrophobic coatings for filtration applications, enhancing water repellency without harmful chemicals.

  3. Thin-Film Battery Materials: Development of 100% silicon anodes for next-generation batteries.

AGC Plasma’s expertise in both sputtering and thin-film technologies ensures tailored solutions for industries ranging from optics and textiles to energy and healthcare, delivering cutting-edge coatings with superior performance and scalability.

Does AGC also provide coating equipment to other architectural and automotive glass manufacturers?

Yes, AGC Plasma supplies advanced vacuum coating equipment for low-emissivity (Low-E) and solar control glass applications not only within the AGC Group but also to external architectural and automotive glass manufacturers worldwide.

A key benefit of partnering with AGC is access to both state-of-the-art coating equipment and well-proven coating recipes. These recipes can be licensed, significantly reducing time to market for new glass products.

AGC also offers a powerful expert system that assists production teams with real-time decision-making. This system uses advanced pattern recognition and machine learning to:

  • Optimize process tuning
  • Predict the impact of coater conditions on final product performance
  • Identify anomalies and correlations in real time
  • Improve yield, reduce variation, and boost throughput

This is particularly important for producing high-performance coatings, such as temperable and non-temperable double and triple silver Low-E glass, which demand tight control and consistency.

By combining proven hardware, licensed process know-how, and digital tools, AGC prepares glass manufacturers for a more efficient, data-driven, and future-ready production environment.

In which other application areas beyond architectural and automotive glass does AGC Plasma apply its expertise in anti-reflective and reflective thin-film coatings and coating equipment?

AGC Plasma is a global leader in thin-film coating technologies, extending its expertise far beyond architectural and automotive glass. Our PVD and PECVD equipment is used for the mass production of advanced anti-reflective (AR) and reflective coatings to enhance optical performance, energy efficiency, and product value across a broad spectrum of high-tech industries.

Key application areas include:

  1. Telescope Mirror Coating Equipment
    AGC Plasma designs and supplies specialized vacuum coating systems for astronomical mirrors, including projects like the European Extremely Large Telescope (ELT) and Instituto de Astrofísica de Canarias (IAC). These coatings ensure exceptional reflectivity and uniformity critical for cutting-edge astronomical observation.
  2. Picture Framing Glass
    AGC Plasma delivers equipment solutions for the production of anti-reflective glass used in picture framing. Our systems support single- and double-sided AR coatings that preserve artwork visibility by minimizing glare and light distortion, while maintaining durability and color neutrality.
  3. LiDAR Systems for Automotive and Industrial Use
    We develop custom AR coatings optimized for narrow infrared wavelengths (e.g., 905 nm and 1550 nm), improving LiDAR signal strength, accuracy, and range. Our coatings are engineered for wide-angle performance and comply with stringent eye safety standards.
  4. Luxury Watch Crystals
    Using ion implantation or thin-film AR coatings on synthetic sapphire glass, the equipment of AGC Plasma allows to enhance dial legibility by reducing glare and achieving the “invisible crystal” effect. The equipment offers the possibility for single- or double-sided treatments tailored for clarity and durability in high-end timepieces.
  5. Electronics & Display Technology
    Our AR coatings minimize reflections and improve contrast on display cover glasses for infotainment systems. Additionally, we provide partially reflective coatings for Head-Up Displays (HUDs) in automotive and aviation sectors.
  6. Solar Energy Systems
    AGC Plasma partnered with a start-up to prototype optical filters for Concentrated Solar Power (CSP) and photovoltaic panels, boosting solar collection efficiency
  7. Aerospace: Aircraft Canopies & Visors:  We offer equipment to apply AR and reflective coatings that reduce solar glare for pilots and apply stealth-enhancing films—such as gold or indium tin oxide (ITO)—to lower radar signatures on aerospace components.
  8. Roll-to-Roll equipment for Optical Interference Coatings on Polymer Films: AGC Plasma developed dielectric multilayer coatings on flexible polymer substrates using roll-to-roll vacuum systems. These coatings provide solar control, glare reduction, and spectrally selective reflection, ideal for window film production.

AGC Plasma’s comprehensive thin-film coating expertise enables customized, high-quality solutions that meet the demanding requirements of advanced optical, energy, and aerospace applications worldwide.

What are the main applications for the water repellent treatment?

For decades, PFAS (per- and polyfluoroalkyl substances) have been widely used to provide water and stain repellency in textiles and technical fabrics. Today, however, rising regulatory pressure and growing consumer demand for safer materials are accelerating the shift to PFAS-free water repellent solutions.

AGC Plasma’s PlasmaMAX™ PECVD technology offers an advanced, fluorine-free alternative. It applies ultra-thin, breathable nanocoatings that deliver durable water and stain resistance—without the environmental concerns of PFAS.

Main application areas include:

  • Medical membranes – providing moisture resistance in protective medical textiles
  • Acoustic membranes – protecting speakers and microphones from water and dirt
  • Air filtration media – enhancing performance in HVAC and cleanroom systems

This PFAS-free water-repellent treatment has been successfully implemented on a roll-to-roll pilot coater at AGC Plasma’s demonstration center. It is available for customer trials, proof of concept, and pilot production.

AGC’s sustainable thin film coatings help manufacturers meet environmental targets while maintaining high product performance in filtration, acoustic protection, and medical membrane applications.

What other innovations have been developed by AGC Plasma for the functionalization of textiles and non-wovens beyond the PFAS-free water repellent treatment?

Beyond water and stain resistance, thin film coatings applied via magnetron sputtering in roll-to-roll systems enable a wide range of advanced functionalities for textiles and non-wovens.

AGC Plasma’s technologies are used to produce multi-layered metallized fabrics with applications in both technical and medical fields. By sputtering metals such as silver, copper, nickel, and tin, we create coated textiles that deliver:

  • Electromagnetic shielding – for EMC-shielded tents, protective garments, and signal-blocking fabrics
  • Infrared and thermal camouflage – for military textiles, protecting personnel and equipment against IR sensors and thermal imaging
  • Antibacterial and antimicrobial protection – using silver or copper coatings in wound dressings, masks, or hygiene-related textiles

 

AGC Plasma also participated in the NANOBLOC Horizon Europe project, supporting the development of antiviral and antibacterial nanocoatings for personal protective equipment and other critical surfaces (nanobloc.eu).

Our thin film technology enables manufacturers to combine functionality, durability, and sustainability in smart textile and non-woven innovations.

What are the advantages of magnetron sputtering over electrodeposition for wear coatings on tools and press plates? What are the best PVD coatings to consider?

Magnetron sputtering (PVD) is a modern, high-performance, and environmentally safe technology that is superior to traditional hard chrome plating. It effectively replaces older electrodeposition processes to eliminate harmful emissions while delivering better results.

Here are the key advantages of using magnetron sputtering:

  • Eliminates Toxic Chemicals: The primary driver for this shift is environmental and safety compliance. Our process is clean, operates in a vacuum, and completely eliminates the use of and exposure to toxic hexavalent chromium (Cr6+), meeting strict global regulations like REACH.
  • Superior Hardness and Wear Resistance: PVD coatings are significantly harder and more durable than traditional hard chrome. This is critical for high-wear applications, such as extending the life of industrial press plates used in the laminate and decorative panel industry. The result is reduced downtime and improved product quality.
  • Unmatched Versatility: Magnetron sputtering can deposit a wide range of advanced coatings, allowing us to tailor the surface properties to your exact needs. Some common industrial anti-wear coatings are:
    • TiN (Titanium Nitride): For general-purpose hardness and wear resistance.
    • CrN (Chromium Nitride): For excellent corrosion resistance and anti-stick properties
    • TiB₂ (Titanium Diboride): For extreme abrasion resistance against abrasive materials.
  • Proven Experience and Turnkey Solutions: AGC Plasma has proven, hands-on experience in helping customers make this exact transition. As highlighted in our recent success story, we delivered a turnkey coating equipment solution for a partner moving from an electrochemical Cr6+ process to an advanced magnetron sputtered wear-resistant layer. This achievement was the result of extensive proof-of-concept testing at our demonstration center in Germany, where we work closely with our partners to engineer and validate the optimal solution before scaling up to industrial production.

In short, magnetron sputtering is the definitive modern solution for creating high-performance, wear-resistant coatings for demanding applications like press plates in a safe and sustainable way.

How is AGC Plasma advancing coating solutions for electrolyzers?

AGC Plasma is at the forefront of the green hydrogen economy, engineering and supplying advanced thin-film coating solutions that are critical for the performance, durability, and cost-effective manufacturing of Proton Exchange Membrane (PEM) Electrolyzers. Our technology directly addresses the core challenges related to key components like the Porous Transport Layer.

1. High-Performance Coatings for Porous Transport Layers (PTLs)

The Porous Transport Layer is a critical component that manages the flow of gases and water while providing electrical contact. Its performance is heavily dependent on its surface properties, and AGC provides specialized PVD (Physical Vapor Deposition) coatings that deliver:

  • Excellent Corrosion Resistance: Our coatings protect the metallic PTLs (often made of titanium) from passivation and corrosion in the highly acidic environment inside a PEM stack. This ensures stable, long-term performance and increases the operational lifetime of the system.

  • Low Interfacial Contact Resistance (ICR): We engineer coatings that ensure excellent and stable electrical conductivity. A consistently low ICR is essential for minimizing electrical losses and maximizing the overall efficiency of the electrolyzer.

2. Scalable Systems for Mass Production

A key barrier to the widespread adoption of hydrogen technology is the need for high-volume, cost-effective manufacturing. AGC Plasma bridges this gap directly:

  • From R&D to Mass Production: We support our partners from the initial R&D and prototyping phase all the way to full-scale industrialization. Our demonstration center is capable of handling large-format samples with maximum dimensions of 1750 mm x 1500 mm, allowing for development on industrially relevant sizes.

  • High-Throughput Inline Coaters: Our specialty is designing and building scalable inline PVD systems that are optimized for the mass production of coated PTLs, ensuring the lowest possible cost of ownership and enabling the production volumes required by the automotive and energy industries.

3. Driving Innovation Through Advanced Technology

We believe in the power of partnership and continuous investment in technology to accelerate progress. A key example of this is the recent upgrade of one of our pilot lines, which is now equipped with:

  • A dedicated pre-etching zone to prepare the substrate surface for optimal adhesion.
  • HiPIMS (High-Power Impulse Magnetron Sputtering) power supplies.

This state-of-the-art setup is specifically designed for depositing corrosion protective layers, such as Platinum (Pt). The process uses an undercoat to ensure excellent adhesion, while the HiPIMS technology produces a dense and uniform Platinum layer, which is vital for maximizing corrosion resistance efficiency and the long- term durability of the PTL.

How does AGC ‘s technology contribute to Thin-Film Battery manufacturing?

PVD (Physical Vapor Deposition) and PECVD (Plasma Enhanced Chemical Vapor Deposition) are essential technologies for the mass production of next-generation thin-film batteries. AGC Plasma is at the forefront of this revolution, leveraging these processes to manufacture key battery components that deliver higher energy density, faster charging, and improved safety.

Our contribution focuses on three critical areas:

1. Manufacturing Advanced Anodes

  • 100% Silicon Anodes (via PECVD): We use our proprietary PlasmaMAX™ PECVD technology to deposit uniform layers of pure silicon onto copper foil. Silicon anodes can store significantly more energy than traditional graphite anodes, a crucial step for extending the range of electric vehicles. We have successfully developed a roll-to-roll pilot line for this process in partnership with industry innovators.

  • Lithium Metal Anodes (via Thermal Evaporation - PVD): Our thermal evaporation systems enable the deposition of ultra-thin (<50 µm), high-purity lithium metal layers. This advanced PVD method overcomes the limitations of traditional manufacturing, allowing for the creation of high-performance, next-generation anodes.

2. Depositing Solid-State Electrolytes and Cathodes

  • Solid-State Electrolytes (via Magnetron Sputtering - PVD): We utilize magnetron sputtering to deposit solid-state electrolytes, such as Lithium Phosphorus Oxynitride (LiPON), lithium lanthanum zinc oxide (LLZO) and lithium lanthanum titanium oxide (LLTO). This technology is critical for developing safer, more stable, all-solid-state batteries. Our innovation in this area includes enabling the use of DC sputtering, which is far more suitable for mass production than conventional RF sputtering.

3. From R&D to Mass Production: Turnkey Solutions

Our key contribution is bridging the gap between lab-scale innovation and industrial mass production. With over 40 years of experience, we design and build custom Roll-to-Roll (R2R) and Sheet-to-Sheet coating systems that enable our partners to scale up their battery material production efficiently and cost-effectively. We are also pioneering future-proof concepts like continuous air-to-air systems to further revolutionize manufacturing scalability.

Whether you are developing silicon anodes, solid-state electrolytes, or other advanced battery materials, AGC Plasma has the expertise and technology to help you scale.

What type of coating system is best for thin-film battery development and production?

The best coating system for thin-film battery materials depends entirely on your stage of development and production scale. AGC Plasma provides tailored solutions for every step of the journey, from initial research to
full industrial mass production.

1. For R&D and Pilot-Scale Development

  • Batch Coating Systems: These are ideal for testing new material compositions and coating processes on small, individual samples (coupons) or rigid substrates. They offer maximum versatility for experimentation.

  • Compact Roll-to-Roll (R2R) Pilot Coaters: For developing processes on flexible substrates like copper or aluminum foils, a pilot-scale R2R system is essential. These systems are designed to validate the coating process, test material durability, and produce sample batches for cell assembly and testing, proving the viability of the technology before major investment.

2. For Industrial Mass Production

When scaling up to high-volume manufacturing, the focus shifts to throughput, reliability, and low cost of ownership. Large-Scale Roll-to-Roll (R2R) Systems are the definitive solution for the mass production of flexible battery components like silicon anodes, lithium metal anodes, and solid electrolytes. Our industrial R2R systems are engineered for continuous, high-speed operation, ensuring maximum productivity and unifor quality across kilometers of material.

AGC's End-to-End Partnership

Our unique strength lies in our ability to be a long-term partner. We can help you validate your process on one of our pilot lines and then design and build a turnkey industrial system that is perfectly scaled for your production targets

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