This Letter reports a generalized theory of the smallest diameter of metallic nanorods from physical vapor deposition. The generalization incorporates the effects of nanorod separation and those of van der Waals interactions on geometrical shadowing. In contrast, the previous theory for idealized geometrical shadowing [Phys. Rev. Lett. 110, 136102 (2013)] does not include any dependence on nanorod separation and it predicts the diameter to be about 1/2 to 1/3 of what the generalized theory does. As verification, numerical solutions and the generalized theory in closed-form agree in terms of effective deposition flux. As validation, experiments of physical vapor deposition and the generalized theory agree in terms of the diameter as a function of the separation of nanorods. The diameter of metallic nanorods from physical vapor deposition (PVD) is a critical quantity that defines their functionalities, such as mechanical strength [1][2][3] and sensitivity in surface enhanced Raman spectroscopy [4][5][6]. Conventional PVD processes typically lead to the growth of thin films [7,8]. Under glancing angle deposition (GLAD), PVD processes result in the growth of nanorods [9,10]. As atoms arrive on a substrate with a glancing angle that is close to 90 o , they land at peaks and avoid valleys due to geometrical shadowing effects. As an effect of positive feedback, the peaks grow into nanorods due to geometrical shadowing. In the processes of nanorod growth, multiple-layer surface steps form and impose three-dimensional (3D) Ehrlich-Schwoebel (ES) barriers [11,12] that are larger than the conventional ES barriers from monolayer surface steps [13,14].The diameter of nanorods is the smallest when the 3D ES barriers dominate or equivalently when multiple-layer surface steps bound the top of nanorods [15] under a given geometrical shadowing condition. The geometrical shadowing goes to complete or ideal as the incidence angle approaches 90 o . Under this idealized condition, all atoms will be deposited on the top surface of nanorods with none reaching their side surfaces, independent of nanorod separation. For such idealized geometrical shadowing, we recently reported a closed-form theory of the smallest diameter [15].Going beyond the idealized shadowing condition, we here report a generalized theory, in closed-form, with non-ideal shadowing conditions and with the effects of van der Waals (vdW) interactions. Figure 1 schematically illustrates the generalization of a nanorod growth process. The direct deposition on the top results in a diameter of the core (orange in the figure), which is governed by our previous theory [15]. The deposition on the sides gives the thickness of the shell (tan in Fig. 1), and it depends on the separation of nanorods. Further, due to vdW interactions, the atomic flux on the 1 Author to whom correspondence should be addressed; electronic mail: h.huang@northeastern.edu top is greater than on the side of nanorods, as indicated by the denser flux lines in Fig. 1. FIG. 1. Schematic of nanorod growth,...