In high-performance 3D metallization, manufacturers are under constant pressure to deliver complex decorative and functional finishes with absolute consistency. At the same time, they must maintain high throughput, reduce waste and keep processes flexible enough to handle different materials and designs. Traditional single-cathode systems can meet some of these requirements, but they often force a compromise between productivity, versatility and process control.
The introduction of dual-independent cathodes in advanced in-line sputtering systems has changed this scenario. By enabling the deposition of two distinct metal layers in a single continuous cycle, solutions like the Tapematic S8+4 establish a new benchmark for 3D metallization performance, combining speed, precision and sustainability in one integrated platform.

3d metallization for demanding industries

Sectors such as cosmetics, beverage, pharmaceuticals and automotive rely on 3D metallization to enhance both appearance and function. Packaging and components must look premium, protect contents, withstand handling and often contribute to technical performance. Reflective finishes, selective metallization, high mechanical resistance and conductivity are increasingly requested on the same part.
To respond to these demands, manufacturers require systems that can deliver high volumes without sacrificing detail. In-line sputtering combined with advanced automation has emerged as one of the most effective answers, especially when integrated into modular lines such as Tapematic PST Line II. Within this framework, dual-independent cathodes provide the extra flexibility needed to create complex multilayer structures efficiently.

What dual-independent cathodes bring to sputtering

In a conventional sputtering system, a single cathode deposits one metal layer per cycle. Any change in material or sequence typically requires additional passes or separate equipment. Dual-independent cathodes change this logic by allowing two different metals or two distinct layer configurations to be deposited in one uninterrupted process.
Each cathode in the S8+4 module operates independently, with its own parameters and control. This offers several advantages:

• two separate metal layers in a single in-line cycle
• tailored combinations of decorative and functional coatings
• reduced handling between processes
• shorter overall cycle times

By concentrating multiple sputtering steps into a unified sequence, dual-independent cathodes eliminate the need for additional machines or offline treatments, simplifying line layout and improving process stability.

Decorative freedom and functional performance in one pass

Modern packaging often requires a combination of decorative effects and functional properties. A component might need a highly reflective metallic surface combined with areas of transparency, or a visually attractive finish that also provides mechanical protection or electrical behavior.
With dual-independent cathodes, manufacturers can design coating stacks that serve both roles in a single pass. For example, one cathode can focus on creating a decorative 3D metallization layer, while the second deposits a film optimised for mechanical resistance, barrier properties or conductivity.
This architecture supports:

• infinite combinations of colours and visual effects
• selective tuning of gloss and reflectivity
• coatings that withstand impacts, friction or aggressive contents
• structures that support electronic or sensor integration

The ability to combine these properties without breaking the in-line flow is what makes dual-independent cathodes a genuine step forward for high-value applications.

Process stability, throughput and repeatability

Production stability is critical whenever 3D metallization is applied to millions of units. The S8+4 module has been engineered to deliver high throughput with tightly controlled parameters, ensuring uniformity even at elevated line speeds. The combination of dual-independent cathodes and advanced automation maintains excellent process stability, uniform deposition and repeatable results from batch to batch.
Key benefits include:

• consistent coating thickness across all parts
• reduced deviation in optical and functional properties
• minimised reject rates due to process drift
• robust operation under continuous high-volume conditions

Because both cathodes are fully integrated into the same in-line sputtering environment, transitions between layers are perfectly controlled. This leads to a more predictable outcome and a significant improvement in global process capability compared to multi-step, multi-machine setups.

Integration with PST Line trays and in-line automation

A crucial factor behind the performance of dual-independent cathodes in the Tapematic S8+4 is their integration with the PST Line handling philosophy. The use of a standardized tray concept across the entire line ensures that each part follows a stable and repeatable path through cleaning, pre-treatment, UV coating, 3D metallization and final curing.
This combination of tray handling systems and in-line sputtering provides:

• precise positioning of every component under each cathode
• smooth transitions between different process stages
• low risk of contamination or misalignment
• optimised setup times when changing products

Because the same trays are used throughout PST Line II and compatible modules, S8+4 can be integrated either as part of a full-scale line or as a standalone unit connected to existing coating systems. In both cases, dual-independent cathodes operate within a controlled, automated ecosystem that supports high productivity and quality.

Sustainability and resource efficiency

Sustainability is now a core requirement for metallization processes. Dual-independent cathodes contribute to more responsible production by reducing the number of passes, machines and handling operations required to reach a given specification. Fewer process steps mean less energy consumption, fewer opportunities for scrap and a more compact line layout.
The S8+4 design emphasises:

• optimised vacuum management
• intelligent power distribution
• controlled material usage
• low-waste handling and automation

By generating high-quality multilayer coatings in a single in-line cycle, dual-independent cathodes help manufacturers lower their environmental footprint while maintaining or enhancing decorative and functional performance. This aligns with the broader focus of Tapematic on combining sustainable design, advanced automation and 3D metallization in a single technology platform.

Flexibility across multiple high-value industries

Because dual-independent cathodes can work with both conductive and mechanically resistant substrates, the S8+4 module is suited to a wide spectrum of applications. These include premium cosmetic packaging, beverage caps and closures, pharmaceutical components, high-performance automotive parts and other technical items that require complex multilayer structures.
Manufacturers can adapt the configuration of each cathode to match different market needs:

• decorative metallization for luxury packaging
• protective layers for harsh environments
• conductive or shielding coatings for electronic integration
• hybrid solutions that combine several functions in one structure

This flexibility makes dual-independent cathodes an attractive investment for companies that need to serve diverse sectors while keeping their production infrastructure streamlined and efficient.

A future-ready standard for 3d metallization

As requirements for 3D metallization continue to grow in complexity, systems that combine performance, flexibility and sustainability will define the future of surface finishing. Dual-independent cathodes in in-line modules such as Tapematic S8+4 already embody this evolution, setting a new standard in how metal layers are applied to three-dimensional components.
By integrating dual-independent cathodes with PST Line II, tray handling systems, UV coating systems and advanced automation, Tapematic offers manufacturers a future-ready platform that delivers high throughput, stable quality and reduced environmental impact. For companies looking to push the boundaries of what is possible in 3D metallization, this technology provides a robust and scalable foundation on which to build the next generation of decorative and functional surfaces.