Thin-Film Coating Methods: A Successful Marriage of High-Quality and Cost-Effectiveness- A Brief Exploration

In this review, several cost-effective thin-film coating methods which include dip-coating, spin-coating, spray-coating, blade-coating, and roll-coating are presented. Each method has its set of advantages and disadvantages depending on the type of application. Not all of them are appropriate for large-scale production due to their certain limitations. That is why the coating method should be selected based on the type and size of substrate including the resolution of the required thin-films. The sol-gel method offers several benefits, such as simplicity in fabrication, excellent film uniformity, the capacity to cover surfaces of any size and over vast areas, and a low processing temperature. Nevertheless, these coating methods are somewhat economical and well managed in low-budget laboratories. Moreover, the produced thin-films are homogeneous and have low-surface roughness. Furthermore, some other thin-film deposition methods such as physical vapor deposition (PVD) and chemical vapor deposition (CVD) are also discussed. Since CVD is not restricted to line-of-sight deposition, a characteristic shared by sputtering, evaporation, and other PVD processes, many manufacturing methods favor it. However, these techniques require sophisticated equipment and cleanroom facility. We aim to provide the pros and cons of thin-film coating methods and let the readers decide the suitable technique for their specific application.