The aim of this study was to evaluate the mechanical properties of stainless steel (SS) orthodontic wires coated with zinc (Zn), using a Physical Vapored Deposition (PVD) machine. A total of 100 straight SS orthodontic wires were cut into pieces of 5 centimeters in length and were divided into two groups. Half of the wires were coated with Zn using a PVD machine, and the others remained uncoated. Tensile strength (n = 15), three-point bending (n = 15), and frictional resistance at 0° (n = 10) and 10° (n = 10) were measured to compare the mechanical properties of the Zn-coated and uncoated orthodontic wires using the universal testing machine. The surface of the coated wires was observed by SEM and AFM. An independent t-test, multivariate ANOVA, and measurement ANOVA were used for data analysis. SEM and AFM showed a homogenous Zn layer of 0.28 ± 0.006 µm on the SS wires. The tensile strength and three-point bending strength significantly increased after Zn coating of wires with the PVD method (
P
<
0.05
). The friction resistance significantly reduced at both angulations following the coating procedure. The angle between the wire and bracket had no significant effect on the frictional resistance (
P
>
0.05
). Coating with Zn improved the tensile and load-bending strength of SS orthodontic wires and reduced their frictional resistance which might be advantageous in terms of reducing the risk of root resorption during the orthodontic treatment.