Sustainability
Laser Processes Enable PFAS-Free Functional Coatings
Fraunhofer ILT develops laser-based processes to manufacture PFAS-free functional coatings for industry.
Laser Processes Support the Transition Away from PFAS
Replacing per- and polyfluoroalkyl substances (PFAS) in industrial applications requires more than alternative materials. Fraunhofer ILT is developing laser-based manufacturing processes that enable PFAS-free functional coatings for metal components, plain bearings, seals, and elastomer rollers. The work is being carried out in the RePEEK, EPOS, LEMBAS, and pureWaterSeal research projects.
According to the institute, manufacturing technology is as important as the replacement material itself. Laser processes deliver energy precisely where it is needed, allowing alternative materials to be processed without exposing entire components to the high temperatures required by conventional furnace-based methods.
Hybrid Laser Process for PEEK Coatings
In the RePEEK project, Fraunhofer ILT is developing a hybrid process for applying PEEK-based coatings to heavily loaded metal components such as plain bearings, seals, pistons, and solenoid valves. The process first creates a rough metallic surface layer using laser deposition before locally melting PEEK powder onto the surface, producing a mechanically bonded composite coating.
The institute has also developed a cyclone nozzle for the PEEK powder feed, which improves material utilization and process control. A patent application has been filed for the technology.
Multilayer Coatings for Large Bearings
Building on RePEEK, the EPOS project focuses on depositing multilayer PEEK coatings on large plain-bearing components. The goal is to achieve greater coating thicknesses without heating multi-ton components in industrial furnaces. Industrial partners contribute expertise in coating technology and materials characterization to optimize coating adhesion and long-term performance.
PFAS-Free Release Coatings for Elastomer Rollers
The LEMBAS project targets elastomer rollers used in film production, packaging, paper manufacturing, and medical technology. Instead of conventional silicone coatings, the researchers are investigating high-performance polymers such as PEEK, polyamide, and polypropylene. Laser processing allows these materials to be melted locally while protecting the heat-sensitive elastomer substrate.
The project also includes the development of an intermediate layer to improve adhesion between the substrate and the functional coating.
Seals for Water-Based Lubrication
In the pureWaterSeal project, Fraunhofer ILT and Fraunhofer IWM are developing PFAS-free sealing systems designed for use with water-based lubricants. The approach combines diamond-like carbon (DLC) coatings with laser microstructuring to reduce friction, improve wear resistance, and extend service life.
Initial prototypes are already operating in geothermal pump systems. Further applications under development include passenger vehicles, ship propulsion systems, wind turbines, and agricultural machinery.
Manufacturing as the Key Enabler
The Fraunhofer ILT projects demonstrate that replacing PFAS requires both suitable materials and manufacturing technologies capable of processing them reliably. By locally depositing, melting, or structuring functional coatings, laser processes enable application-specific coating systems while minimizing thermal stress on the underlying components. According to the institute, this approach opens the way for PFAS-free solutions in applications ranging from plain bearings and industrial rollers to sealing systems.
