Bonding behavior studies of cold sprayed copper coating on the PVC polymer substrate

► Thick copper coating (1000 μm) was fabricated on the PVC polymer substrate. ► The bonding mechanism was studied by focused ion beam dissection. ► The coating interlayer effect was studied. ► Large surface area of the dendritic particle was favorable for bond formation. ► The electrical conductivity of the coating was comparable to the bulk copper.