iOSMB Technology: Advancing Thin-Film Coating Precision with Real-Time Magnetic Field Control

In industrial vacuum coating applications, achieving high uniformity over large areas is critical, especially for dielectric and metal layers used in optics, display technology, and solar energy applications. One of the key challenges has been controlling deposition uniformity while maintaining process efficiency. Traditional approaches require pausing the coating process to make adjustments, leading to production downtime and inefficiencies.

AGC Plasma Technology Solutions has introduced the Online Shimmable Magnet Bar (iOSMB), a next-generation technology designed to dynamically control the magnetic field strength distribution in real time during the coating process. This innovative solution allows for precision control of uniformity without interrupting production, significantly improving efficiency in plasma-based vacuum coating applications.

Challenges in Coating Uniformity

Traditional vacuum coating techniques, such as magnetron sputtering, rely on fixed magnetic fields to control plasma generation. However, these systems face several challenges:

Inconsistent Coating Profiles – Variations in the target material's erosion profile lead to non-uniform coatings.
Production Interruptions – Adjustments to the magnetic field require venting the coater, stopping production.
Limited Control for Complex Geometries – Coating on curved or 3D surfaces is difficult to optimize with fixed magnet systems.

These challenges necessitate a more adaptive and real-time approach to controlling deposition uniformity.

iOSMB: A Breakthrough in Magnetic Field Control

1. Real-Time Magnetic Field Adjustments

The iOSMB system enables dynamic tuning of the magnetic field strength by adjusting individual magnet yokes inside the rotatable cathode. This allows for:

Localized control of deposition rate, improving coating uniformity.
Adjustments without stopping production, eliminating downtime.
Fine-tuning of multi-stack coatings and coatings on 3D objects, ensuring high-precision layer profiles.

2. High-Precision Yoke Control

Each iOSMB unit consists of individual magnet yokes, which can be adjusted in height relative to the target. Key features include:

Independent control of each yoke, allowing precise local tuning.
Stroke height adjustment up to 15 mm, providing flexibility for different materials.
Positioning accuracy of 50 µm, ensuring fine control of deposition.
Automated tuning wizard for guided optimization during production.

3. Battery-Powered, Fully Autonomous Operation

The iOSMB system operates without external power connections, relying on an integrated battery system. Key benefits include:

Up to one year of battery life per charge, reducing maintenance frequency.
No risk of power interference, ensuring consistent performance.
Fully dry operation, eliminating corrosion risks associated with water exposure.

Industrial Applications

The iOSMB technology is particularly beneficial in applications requiring high coating uniformity, including:

Architectural Glass & Smart Windows – Ensuring consistent optical coatings for low-E and solar control glass.
Display and Optics – Achieving high uniformity for OLED displays, anti-reflective coatings, and interference filters.
Automotive & Aerospace – Providing precise coatings for scratch-resistant surfaces and reflective layers.
Solar Panels – Enhancing coating uniformity on photovoltaic cells, improving energy efficiency.
Advanced Packaging Films – Ensuring moisture and oxygen barrier coatings for flexible packaging applications.

Advantages Over Conventional Systems

The introduction of iOSMB technology provides several key advantages over traditional magnetron sputtering systems:

Reduces Tuning Time – Adjustments can be made on-the-fly, avoiding costly downtime.
Improves Coating Uniformity – Limits non-uniformities to +/- 0.3% over large-area coatings.
Simplifies Multi-Layer Deposition – Easily adaptable for multi-stack coatings.
Enhances Process Flexibility – Allows quick magnetic field transfers between different iOSMB units.

Conclusion

The iOSMB Online Shimmable Magnet Bar represents a significant advancement in thin-film deposition technology, particularly for applications requiring high coating uniformity over large areas. By enabling real-time control of the magnetic field strength, iOSMB eliminates production downtime and enhances precision control for complex coating processes.

For manufacturers looking to optimize coating uniformity, reduce costs, and improve overall process efficiency, iOSMB technology offers a next-generation solution for high-performance thin-film applications.

For more information on AGC Plasma Technology Solutions and how iOSMB can enhance your production process, visit AGC Plasma Technology Solutions.