When it comes to enhancing the visual appeal and durability of plastic components, few finishing techniques offer the impact and versatility of vacuum metalising. From creating chrome-like mirrors on automotive trims to giving cosmetic packaging that rich metallic shine, this process has become a go-to solution for manufacturers across industries.
But what exactly is vacuum metalising? And why is it used so widely in plastic product manufacturing today?
Here’s a practical guide for product designers, procurement teams, and OEMs who want to understand how vacuum metalising works—and how it can fit seamlessly into their product development process.
Vacuum metalising is a surface finishing technique that deposits a thin layer of metal—typically aluminum—onto a plastic or non-metallic surface within a vacuum chamber. This is done using a process called physical vapor deposition (PVD).
The result? A highly reflective, smooth, and durable metallic finish that can mimic polished chrome, brushed aluminum, or tinted metal. Unlike traditional electroplating, vacuum metalising doesn’t involve heavy chemicals or electrolytic processes, making it cleaner, faster, and more eco-conscious.
It’s particularly well-suited for:
Understanding how vacuum metalising works helps clarify its advantages. The process includes several key stages:
The plastic component—often made using precision tools from a plastic injection moulding factory—is first cleaned thoroughly. Any dust, oil, or residue can interfere with adhesion, so the cleaning process may include plasma treatment or solvent wiping.
If the final part requires a colored base or enhanced adhesion, a base coat is applied through a spray painting process.
Prepared parts are placed on rotating racks inside a vacuum chamber. This ensures even exposure during the metal deposition process.
Inside the chamber, aluminum wire (or another metal) is heated in a filament until it vaporizes. The metal vapor coats the exposed surfaces of the plastic part, forming a thin, uniform metallic layer.
Because the chamber is under vacuum, the metal spreads evenly and bonds well with the surface—no bubbles, pooling, or texture issues.
Once the part is removed from the chamber, a clear protective topcoat is applied. This can be matte, gloss, or tinted depending on the desired final effect. The topcoat protects the metal layer from:
This topcoat is often applied using the same infrastructure used for hydrographics water transfer printing or foil pressed printing—making it easy to integrate with other decoration techniques.
Vacuum metalising provides that iconic metallic look that immediately communicates precision and quality. It enhances product perception across almost any category.
Because the coating is thin (usually 0.1 to 0.2 microns), you retain all the advantages of plastic—light weight, moldability, and cost efficiency—without sacrificing appearance.
This process works seamlessly with foil pressed printing for logos and fine details, or hydro dipping to add textures under the metallic layer. You can combine techniques for a layered, high-end finish.
It’s faster than electroplating and can be scaled for both high- and low-volume production. Once set up, the process supports tight turnaround without the chemical waste associated with traditional metal finishes.
Vacuum metalising is widely used in automotive design because it delivers chrome-like effects without metal weight or corrosion issues. With the right topcoat, these components stand up to heat, sun, and handling.
In cosmetic packaging, the shine of metal conveys luxury. But traditional metal parts are costly to mold and assemble. Vacuum metalised plastic solves both problems.
When used with parts from a plastic injection moulding factory, vacuum metalising adds brand distinction without compromising part design or structure.
| Feature | Vacuum Metalising | Foil Pressed Printing | Hydrographics Water Transfer |
| Metallic Appearance | ✅ Excellent | ✅ Limited (flat areas only) | ❌ Not metallic by itself |
| 3D Coverage | ✅ Full surface | ❌ Mostly flat regions | ✅ Excellent on complex forms |
| Customization | ⚪ Requires setup | ✅ Easy logos/small text | ✅ Full-surface patterns |
| Durability | ✅ High with topcoat | ✅ Medium | ✅ High with protective clear |
Often, vacuum metalising is used in tandem with these finishes. For example, you might dip a part in hydrographics, metalise it, and then apply foil-pressed branding—all managed within one controlled workflow.
At Rustagi Polymers, vacuum metalising is a core part of our integrated finishing services. We support your product vision from part design to ready-for-market execution.
Whether you’re looking to build a premium line of lifestyle accessories or scale up automotive interior components, we’ll help you deliver the metallic impact your customers expect—without compromising speed or cost.
When it comes to enhancing the visual appeal and durability of plastic components, few finishing techniques offer the impact and versatility of vacuum metalising. From creating chrome-like mirrors on automotive trims to giving cosmetic packaging that rich metallic shine, this process has become a go-to solution for manufacturers across industries. But what exactly is vacuum […]
