The development of multilayer partial coating introduces a new and more flexible way to deposit thin-film coatings on large glass surfaces. This method combines the benefits of high-precision material placement, reduced process complexity, and improved material efficiency — making it especially relevant for industries seeking to integrate functional features into glass without compromising on cost or scalability.
What Is Multilayer Partial Coating?
In multilayer partial coating, one or more thin film layers are deposited only on specific areas of the glass surface. Unlike traditional full-surface coating methods, which often require masking or post-process etching, this technique allows coatings to be applied exactly where needed. This is particularly valuable in applications where only a small area of a large glass pane requires functional treatment — for example, to add sensor interfaces, touch elements, or shielding layers.
The process is based on established physical vapor deposition (PVD) techniques, such as magnetron sputtering, but is implemented in a more compact, modular setup. The coating area is defined by the mechanical design of the equipment and an adjustable aperture, which allows precise control of the coating zone. Different source materials are introduced one at a time through the same aperture, enabling the deposition of multilayer stacks in a single vacuum cycle, without exposing the glass to ambient air between layers.
Key Advantages
Multilayer partial coating brings several technical and operational benefits:
- Perfect alignment between layers: Since all coatings are applied without moving the substrate, the resulting stack is inherently aligned.
- Material and energy savings: Only the necessary amount of coating material is consumed; there is virtually no overspray or waste.
- Process speed and simplicity: The entire coating stack is completed in one vacuum run, eliminating intermediate cleaning or pumping cycles.
- Support for complex geometries: The system can be adapted to both flat and shaped glass surfaces through interchangeable form-fitting modules.
- Compact equipment footprint: The technology allows for smaller, more cost-effective machines that can function either inline or as standalone units.
Applications and Use Cases
Multilayer partial coating is well-suited to industries where localized functionality on glass is required:
- Architecture: Smart glass with embedded control areas, heating zones or sensor regions.
- Automotive: Functional layers in windshields or side windows—e.g., for defogging or display integration.
- Electronics: High-precision coatings for displays, optical filters or embedded electronics.
By focusing only on the necessary area, the method enables new product concepts that would be cost-prohibitive with conventional full-surface coatings.
A Scalable and Sustainable Solution
The technology builds on mature coating methods, but introduces a more efficient and flexible way to apply them. Reduced material consumption, shorter cycle times, and smaller equipment sizes support sustainability targets and open new opportunities for commercial innovation.
While industry adoption may require familiarization and further development, the foundational processes are well-known and technically reliable. Continued research and collaboration between manufacturers, research institutes, and equipment developers will help unlock the full potential of multilayer partial coating in advanced glass applications.
More information at the GPD 2025 event
