Color options
Bright chrome/aluminum, brushed metal look, tinted metallics (gold, gunmetal, bronze) via top coat
Vacuum Metallizing for Injection Molded Parts
Vacuum metallizing deposits a thin aluminum layer onto a plastic part inside a vacuum chamber, giving it a bright, chrome-like metallic finish. It's a lower-cost, lighter-weight alternative to electroplating, with a different durability profile worth understanding before specifying it.
0.1-2μmAluminum metal layer
What Vacuum Metallizing Does
Vacuum metallizing works by heating a metal source — typically aluminum — inside a vacuum chamber until it vaporizes, then letting that vapor travel in a straight line and condense onto the part's surface as a thin, reflective metal layer. The part usually gets a smooth base coat first so the metal layer has something even to bond to, and a clear or tinted top coat afterward to protect the thin metal from oxidizing or wearing away. For a molded part, that combination delivers a premium, metallic appearance — chrome, brushed aluminum, or a tinted metallic color — without the weight or cost of machining actual metal or the more involved chemistry of electroplating.
Suitable materials
ABS and similar smooth-surface, paintable plastics
Metal layer thickness
0.1-2μm aluminum
Wear resistance
Lower than electroplating; protected by a top coat, best suited to low-contact surfaces
Notes
Requires a base coat and protective top coat — the metal layer alone is too thin and fragile to leave exposed
Vacuum Metallizing vs. Electroplating
Both processes put a metal appearance on a plastic part, but they work differently and land in different places on cost and durability.
FactorVacuum MetallizingElectroplating
01ProcessPVD (physical vapor deposition) in a vacuum chamberElectrochemical deposition in a chemical bath
02Typical metalAluminumNickel base + chromium (or other metal)
03Relative costLower (roughly 60-80% less)Higher
04Relative weightLighterHeavier (still far lighter than solid metal)
05Wear resistanceLower — relies on a protective top coatHigher — metal layers themselves resist wear
06Best suited forLow-contact cosmetic surfaces: trim, housings, decorative accentsHigher-contact or higher-durability parts: handles, fixtures, frequently touched surfaces
Need help comparing decorative options? Review all molded-part finishes.
Advantages and Considerations
Advantages
- 01
Costs roughly 60-80% less than electroplating for a comparable metallic appearance.
- 02
Adds far less weight than electroplating or solid metal, since the deposited layer is a fraction of a micron thick.
- 03
No mold cost impact and works across prototype and production volumes, since it's a post-molding process rather than something built into the tool.
- 04
Produces a highly reflective, uniform finish well suited to chrome, brushed metal, or tinted metallic looks.
Considerations
- 01
Wear resistance is meaningfully lower than electroplating — the thin metal layer depends on its top coat for protection, and that top coat can scratch or wear through on a frequently handled surface.
- 02
Not a substitute for electroplating on parts that need durability as well as appearance, such as handles, buttons, or anything with regular hand contact.
- 03
Like electroplating, it amplifies rather than hides surface defects, so the as-molded part needs a clean, smooth, paint-ready surface.
- 04
Typically limited to ABS and similar smooth, paintable substrates — not every resin is a good candidate.
Frequently Asked Questions
Is vacuum metallizing as durable as electroplating?+
No — vacuum metallizing has meaningfully lower wear resistance. The thin aluminum layer is protected by a top coat rather than being inherently wear-resistant the way electroplated metal layers are, so it's better suited to low-contact cosmetic surfaces than handles or frequently touched parts.
Which is cheaper, vacuum metallizing or electroplating?+
Vacuum metallizing is typically 60-80% less expensive than electroplating for a comparable metallic appearance, since it's a simpler vacuum deposition process rather than a multi-step chemical bath sequence.
What materials can be vacuum metallized?+
ABS and similar smooth, paintable plastics are the standard choice, similar to electroplating. The part needs a clean, defect-free surface, since the metallized finish reveals surface flaws rather than hiding them.
Can vacuum metallizing be used on a part that will be handled frequently?+
It's not the best choice for that application. A frequently touched surface — a handle, a button, a grip area — is more likely to scratch through the protective top coat over time. Electroplating holds up better under that kind of repeated contact.
Does vacuum metallizing affect part dimensions?+
No — the deposited metal layer is only 0.1-2μm thick, thin enough that it doesn't meaningfully change part dimensions, similar to electroplating's chromium layer.