Advanced surface solutions for defense and aerospace

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Customized PVD surface coatings, plasma nitriding, and ion implantation that ensure reliable performance under the most demanding operating conditions - from Arctic cold to desert operations.

Components for defense and aerospace must operate safely and reliably under extreme wear, severe temperature fluctuations, vacuum, corrosive environments, and sand/dust exposure – often without the possibility of conventional lubrication or routine maintenance. When a single moving surface fails, the entire system stops.

Danish Technological Institute develops, validates, and manufactures advanced surface treatments and coatings that increase wear resistance, reduce friction, and ensure corrosion protection. We also engineer surfaces with precisely tuned functional properties – electrical, electromagnetic, thermal, and optical - tailored to the specific operating environments your components must withstand.

With more than 35 years of experience as a commercial supplier and R&D partner, along with a complete in-house value chain, we take your project from feasibility study and prototyping to full series production.

Arctic defence vehicle

How can Danish Technological Institute assist you?

Danish Technological Institute's tribology specialists offer a wide range of surface treatments and coatings for defense and aerospace:

Wear protection for gear parts, transmission components, hydraulic rods, firearm mechanisms, and other heavily loaded components
Solid lubrication with DLC coatings for operation without oil and grease – in vacuum, extreme cold, desert environments, and contamination-sensitive systems
Surface hardening with plasma nitriding - significantly increased hardness and wear resistance with minimal distortion
Electromagnetic signature control - thin-film coatings for managing radar, IR, and optical response, as well as EMI shielding
Electrically functional coatings - conductive, semiconductive, or insulating coatings for sensors, contacts, and connectors
Corrosion protection against salt, moisture, aggressive media, and extreme climatic conditions
Consultancy, testing, and development - from tribological troubleshooting to complete R&D project management with advanced in-house characterization
Full traceability and documentation tailored to defense and aerospace industry standards

Tandhjul

DLC – solid lubrication for demanding operational environments

Under harsh operating conditions, traditional lubricants lose their functionality. Oil thickens and freezes in Arctic cold. Grease attracts sand and causes abrasive wear in desert environments. In a vacuum, oil evaporates, and unlubricated metal surfaces seize together (cold welding).

DLC coatings (Diamond-Like Carbon) provide a solid lubricating layer without the environmental limitations characteristic of fluid-based lubricants.

Typical operational environments:

Arctic / high latitudes: Reliable movement down to below -50 °C without oil
Desert / expeditionary environments: Dry and hard surface to which sand does not adhere
Space / vacuum: Oil-free and non-outgassing - tested and well-documented protection for space applications. For several years, Danish Technological Institute has delivered DLC coatings for components that are currently in operation in space

Learn more about DLC coatings

Plasma nitriding – surface hardening for heavily loaded components

Steel components subjected to continuous mechanical wear and loading under harsh conditions require a surface that can withstand millions of load cycles without failure. Plasma nitriding is a proven surface treatment that resolves many of the most common wear challenges in steel components.

Components that benefit from plasma nitriding:

Gears and drivetrain components: hardened tooth flanks resist wear and pitting under sustained cyclic loading, including turret drives, transmissions, and actuator gear trains
Hydraulic rods and actuator rods: hardened, fatigue-resistant surface supporting reliable sealing and extended service life
Firearm mechanisms: bolts, trigger components, and cam surfaces required to withstand millions of high-stress cycles without galling or premature wear
Fasteners and threaded components: improved resistance to galling and fretting in high-vibration environments, relevant for vehicles, aircraft, and naval systems
Spare and legacy parts: a cost-effective method to restore or exceed hardness specifications on locally or additively manufactured replacement parts

Learn more about plasma nitriding

Electromagnetic signature control with thin-film coatings

Modern defense systems demand surfaces that do more than merely protect. They must control how a surface reflects, absorbs, or transmits electromagnetic radiation - from radar and RF frequencies to infrared and visible light. This control over a platform's electromagnetic signature is vital in modern defense technology.

Folie Traditional materials used for managing electromagnetic response are often heavy, bulky, expensive, and difficult to integrate into modern platforms. Precisely engineered thin-film coatings offer a lightweight, ultra-thin alternative without compromising performance.

How it works: Using magnetron sputtering, precisely tuned resistive or conductive surface coatings are deposited in nanometer-thin layers – from single layers to complex multi-layer structures using masking techniques. These engineered thin films decouple the electromagnetic response from the base substrate, providing designers with direct control over the surface's interaction with incoming radiation.

Applications:

Radar, IR, and optical signature management: coatings can be tailored to a single frequency band or broad-spectrum coverage, depending on the application
EMI shielding: protection of sensitive electronics against electromagnetic interference
Lightweight integration: thin surface coatings and structures integrated directly into weight-sensitive platforms such as UAVs
Versatile platform technology: the same core technology enables tuning of electromagnetic response across radar, IR, and optical frequencies

Danish Technological Institute collaborates closely with other Danish competence centers to build leading capabilities in simulation, design, testing, and production of electromagnetically tunable materials with a focus on the radar frequency spectrum.

Functional surfaces for specialized applications

Beyond conventional wear protection and electromagnetic signature control, Danish Technological Institute develops and manufactures functional coating systems tailored to specific technical requirements:

Electrically functional coatings: Conductive, semiconductive, or electrically insulating coatings for sensors, connectors, contacts, and similar components. This includes superconducting niobium films on flexible substrates, providing robust, lightweight transmission lines and connectors.
Optical surfaces: Coatings with controlled reflection and transmission properties for specialized solutions in optics and detection systems.
Protection of sensitive electronics: Ultra-thin metal oxide films providing precise electrical insulation where required – and protecting space systems against environmental degradation, including atomic oxygen.
Barrier coatings for vacuum and fuel cells: Cerium gadolinium oxide (CGO) and other ion-selective barriers that remain stable in vacuum and prevent unwanted gas ingress and outgassing.
Lightweight integration: Nanometer-controlled surface coatings on flexible substrates.

See our different coatings

Proven results: Big Science and space case studies

CERN – electrically insulating PVD coatings for 11 Tesla magnets

Danish Technological Institute custom-developed micrometer-scale electrically insulating PVD coatings for CERN's next-generation 11 Tesla superconducting magnets. The coatings were engineered to provide reliable electrical insulation under severe mechanical stresses and cryogenic temperatures down to approximately -269 °C (liquid helium). The project demonstrates Danish Technological Institute's capability to develop and produce advanced coatings for the most demanding operating conditions in Big Science.
How we helped CERN

ESO – analysis and maintenance of coating equipment for the world's largest telescopes

In collaboration with high-tech company Polyteknik A/S, Danish Technological Institute completed a commercial assignment for the European Southern Observatory (ESO) in the Atacama Desert in Chile. The task involved mapping and analyzing the condition of a 9-meter coating system used to maintain telescope mirrors up to 8 meters in diameter across ESO's four Very Large Telescopes (VLT).
The coating process is based on magnetron sputtering of aluminum, where the coating's micro- and nanostructure must be optimized for peak reflectance – with a coating uniformity across the ~50 m² mirrors exceeding ±5 percent. Facilitated by the Big Science Secretariat, this project highlights how Danish Technological Institute's vacuum coating expertise is applied to the most advanced scientific instruments.

DLC coatings operating in space

For several years, Danish Technological Institute has supplied DLC surface coatings for aerospace components that are currently operating in space. This provides documented proof that our solid lubrication and wear-resistant coatings are fully tested and validated for the extreme demands of space environments.
See more examples of coating applications

Quality, traceability, and documentation

Danish Technological Institute's production of surface coatings is certified according to ISO 9001. For defense and aerospace projects, we provide full traceability and process certificates that ensure batch-to-batch consistency and fulfill stringent audit requirements.

When project specifications dictate, we collaborate with the client to meet the dedicated standards and regulatory requirements of the defense industry.

This is how we work with quality

From development to series production

Danish Technological Institute covers the entire development lifecycle from initial concept to full series production. To ensure an efficient, low-risk transition to commercial manufacturing, our coating development is simulation-assisted and performed in the same systems used for production. This ensures rapid development cycles and direct scalability.

Feasibility study: We evaluate operating conditions and match them with the optimal materials and technologies
Development and testing: We develop and test surface coatings under relevant load conditions using advanced in-house characterization
Prototyping and pilot production: The coating is validated in production-scale systems
Scale-up to series production: Transition to full industrial production in our facilities, including Class V cleanrooms for sensitive components

Danish Technological Institute is a major Danish Research and Technology Organisation (RTO) comprising 32 technology centers and more than 1,000 specialists. Our tribology specialists are a trusted supplier to demanding organizations, including CERN and ESO (European Southern Observatory).

Consultancy and development of surface solutionsr

Contact us regarding your project

Do you have components that must operate reliably under extreme service conditions? Danish Technological Institute's specialists can help you determine the optimal surface solution - from initial consultation to series production.

Henrik Horup Reitz – Phone: +45 72 20 15 48, E-mail: hre@dti.dk
Espen Hvidsten Dahl – Phone: +45 72 20 23 21, E-mail: ehd@dti.dk
Christian Zeuthen (Research & Development) – Phone: +45 72 20 17 18, E-mail: cmz@dti.dk

FAQ

What is PVD coating, and when is it relevant for defense and aerospace?

PVD (Physical Vapor Deposition) is a vacuum-based coating technology that deposits extremely wear-resistant, homogeneous, and dense surface layers on components – ranging from nanometers to micrometers in thickness. PVD coatings are relevant when components are exposed to severe wear, corrosion, extreme temperatures, or vacuum, and where conventional lubrication is unfeasible or undesirable. Danish Technological Institute primarily utilizes magnetron sputtering, which provides nanometer-precise control over coating properties.

Can DLC coatings replace traditional lubrication in Arctic and desert environments?

Yes. DLC (Diamond-Like Carbon) coatings provide a solid lubricant surface that performs reliably below -50 °C and in desert environments, where grease attracts sand and induces abrasive wear. DLC provides a dry, hard surface that resists sand adhesion and does not stiffen or freeze in the cold. Danish Technological Institute offers three DLC variants: DLC-TR (standard), DLC-Si (enhanced hardness and thermal stability), and IBAD-DLC. Danish Technological Institute has supplied DLC coatings for space flight components currently operating in orbit.

What is plasma nitriding, and what challenges does it resolve?

Plasma nitriding is a thermochemical case-hardening process that diffuses nitrogen into the steel surface, increasing surface hardness up to 1200 HV with minimal dimensional distortion. The process resolves issues related to wear, pitting, fatigue, galling, and fretting on heavily loaded steel components such as gear components, hydraulic rods, firearm mechanisms, and fasteners. When combined with post-oxidation (PLASOX), it provides enhanced corrosion protection as well.

What is electromagnetic signature control with surface coatings?

Electromagnetic signature control involves managing how a surface reflects, absorbs, or transmits electromagnetic radiation – including radar, IR, and optical frequencies. Danish Technological Institute designs thin-film coatings via magnetron sputtering that decouple electromagnetic response from the structural substrate, providing precise control over a platform's signature. Coatings can be tailored for discrete frequency bands or broadband performance.

Which quality standards does Danish Technological Institute comply with?

Danish Technological Institute's coating production facility is certified according to ISO 9001. For defense and aerospace projects, we provide complete traceability and process certification customized to client-specific requirements and audit standards.

Can Danish Technological Institute take a project from concept to series production?

Yes. The Tribology Center at Danish Technological Institute manages the complete development lifecycle – from feasibility studies and simulation-assisted coating development to prototyping, pilot production, and full-scale industrial manufacturing. Development and production take place in the same equipment, ensuring rapid iteration cycles and direct scalability. Advanced coatings can be processed in Class V cleanrooms.

What sets Danish Technological Institute's surface solutions apart from other suppliers?

Danish Technological Institute combines more than 35 years of experience with three complementary surface technologies (PVD, plasma nitriding, and ion implantation up to 180 kV), advanced analytical instrumentation, Class V cleanroom facilities, and ISO 9001-certified production. As part of a major Danish RTO with 32 technology centers and over 1,000 specialists, we provide independent consultancy and a complete in-house value chain. We are a trusted supplier to organizations such as CERN and ESO.