PFAS-free coatings are here to stay. With growing health and environmental concerns, industries are rapidly replacing PFAS with safer, eco-conscious alternatives. These replacements offer comparable performance without the risks tied to "forever chemicals."
Key Takeaways:
- Why it matters: PFAS chemicals are linked to serious health risks and environmental harm. Over 200 million Americans face unsafe PFAS levels in tap water.
- Market shift: The PFAS-free coatings market is projected to grow from $1.5 billion in 2024 to $2.1 billion by 2030.
- Top Alternatives:
- Silicone Water Repellents: Strong water resistance, lower toxicity, but sensitive to pH extremes.
- Nanotech Surface Coatings: Superhydrophobic with durable, cost-effective applications.
- Plant-Based Repellents: Bio-based, fluorine-free, and breathable.
- Sol-Gel Coatings: Ceramic-based, heat-resistant, and eco-friendly.
- Plasma Surface Treatments: Ultra-thin, long-lasting, and solvent-free.
- Polyurethane Coatings: Waterborne, biodegradable, and durable.
- Non-Fluorine Polymers: Stain-resistant and highly adaptable for textiles and packaging.
Quick Comparison:
| Alternative | Water Repellency | Eco-Friendliness | Durability | Key Limitation |
|---|---|---|---|---|
| Silicone Water Repellents | Excellent | Lower toxicity | Good | Sensitive to pH extremes |
| Nanotech Coatings | Exceptional | High | High | Cost for advanced formulations |
| Plant-Based Repellents | Good | Bio-based, fluorine-free | Moderate | Limited heat resistance |
| Sol-Gel Coatings | Good | Low carbon footprint | High | Thicker coating required |
| Plasma Treatments | Excellent | Solvent-free | Long-lasting | Initial setup cost |
| Polyurethane Coatings | Very Good | Biodegradable | High | Limited oil repellency |
| Non-Fluorine Polymers | Good | Fluorine-free | High | May require reapplication |
Why It Matters:
Switching to PFAS-free solutions is not just about meeting regulations; it’s about protecting health and reducing environmental risks. These alternatives are paving the way for safer, more sustainable industries. Dive into the details to find the best fit for your needs.
Replacing PFAS Coatings Using Bio-based Alternatives
1. Silicone Water Repellents
Silicone water repellents provide strong water resistance while being more eco-conscious. With surface energy measurements of 20 mN/m - close to the 13–20 mN/m range found in PFAS compounds - silicone polymers deliver similar performance in various applications [4].
Recent developments have introduced silicone quaternary ammonium compounds that achieve a 115° contact angle. Additionally, Q resin formulations now score 4 in AATCC 193 tests, surpassing the typical score of 3 for PFAS, showcasing their competitive performance [4].
Silicone treatments also enhance fabric strength and reduce water absorption, which is particularly helpful for materials like nylon, as it retains its durability even when wet [3].
However, silicone coatings have some drawbacks. Their Si–O–Si bonds can degrade in highly acidic or basic environments, and their thermal stability is limited to about 150°C (302°F) [4]. To address environmental concerns, manufacturers have worked on reducing residual cyclic siloxanes, improving safety standards [2].
Here's a breakdown comparing silicone water repellents and traditional PFAS coatings:
| Feature | Silicone Repellents | PFAS Coatings |
|---|---|---|
| Water Repellency | Excellent (115° contact angle) | Excellent (113–120° contact angle) |
| Environmental Impact | Lower persistence, reduced toxicity | High persistence, significant health risks |
| Chemical Stability | Moderate; sensitive to pH extremes | Very high; resistant to degradation |
| Cost Effectiveness | Lower material costs | Higher material costs |
| Mold Resistance | High protection | High protection |
| Durability | Good with proper care | Excellent, but raises environmental concerns |
Silicone water repellents are widely used across industries. In the automotive sector, they protect interiors and improve the self-cleaning features of exterior surfaces [6]. In textiles, these treatments offer reliable moisture protection while preserving breathability - essential for outdoor gear and performance clothing [5].
With a focus on eco-conscious practices and proven performance, silicone water repellents are emerging as a practical alternative to PFAS coatings for manufacturers aiming for greener solutions in 2025. Up next, we'll dive into nanotech surface coatings as another PFAS-free innovation.
2. Nanotech Surface Coatings
Nanotech surface coatings provide an alternative to PFAS-based treatments by using nanoparticles to mimic the structure of lotus leaves [8].
The Leibniz Institute for Plasma Science and Technology (INP) has developed organosilicon polymer coatings known for their durability. Dr. Frank Hempel, Head of the Plasma Surface Technology Department at INP, highlights:
"The organosilicon polymer layer is a promising alternative to PFAS-containing layers and offers broad industrial applications" [1].
These coatings achieve superhydrophobic properties, with contact angles exceeding 160° [8]. Advanced self-assembled monolayer (SAM) surfaces further enhance this, achieving sliding angles as low as 0.01° [7]. This exceptional water repellency opens doors to a variety of industrial uses.
Industries and Applications
Nanotech coatings are already making an impact across multiple sectors:
| Industry | Application | Benefits |
|---|---|---|
| Medical Devices | Hydromer's PFAS-free hydrophilic coatings | Improves biocompatibility and reduces friction in catheters and stents [9] |
| Electronics | Fujifilm's KrF photoresist | Offers a PFAS-free solution for semiconductor production [9] |
| Energy Storage | Nanoramic's 3D nanocarbon binding | Replaces PFAS in lithium-ion batteries without sacrificing performance |
| Automotive | INP's organosilicon coatings | Provides stable, washable coatings suitable for heat-sensitive plastics [1] |
A single liter of these coatings can cover up to 2,700 ft² (250 m²) using just 8–10 g per m², cutting costs by as much as 90% in certain applications [11][12].
Added Durability and Protection
These coatings shield surfaces from damage caused by abrasion, corrosion, fading, and staining. Research by Kotnarowska et al. demonstrated that epoxy-polyurethane coatings enhanced with silica or alumina nanoparticles offered superior resistance to erosive wear over three years compared to traditional coatings [10].
Companies like Novec have also introduced specialized solutions. For example, Novec 4200 works well with buffered oxide etchants, while Novec 4300 is designed for phosphoric, acetic, and nitric acid applications. These products maintain high performance while addressing environmental concerns tied to PFAS [9].
3. Plant-Based Repellents
Plant-based water repellents are gaining traction as eco-friendly, high-performance options for textiles and surface coatings.
One standout is Rudolf Group's BIONIC-FINISH® ECO, which uses a dendrimer-based treatment to create a durable, fluorine-free layer on textile fibers. According to RUDOLF:
"BIONIC-FINISH® ECO is a patented fluorine‑free technology from RUDOLF that effectively protects textiles from rain and water‑based stains" [13].
Leaders in Bio-Based Content
Several products lead the way with high levels of bio-based content:
| Product | Bio-Based Content |
|---|---|
| RUCO‑DRY® BIO CGR | 87% |
| RUCO‑DRY® ECO ADV | 74% |
| UNIDYNE XF‑4001 | >65% |
| RUCO‑DRY® ECO NCB | 43% |
Innovative Manufacturing Techniques
Natural carnauba wax plays a key role in these repellents. During processing, it dissolves in water to form anionic particles that bond with cellulose fibers [17]. These treatments can be applied through dipping, spraying, or brushing, all while maintaining the fabric's breathability [17].
Growing Market and Consumer Interest
The appeal of plant-based repellents is reflected in market growth and consumer preferences. Nielsen research shows that 66% of global consumers are willing to pay more for environmentally friendly products, with Millennials leading at 73% [16]. Daikin’s UNIDYNE XF Series exemplifies this trend, offering fluorine-free finishes made from over 50% bio-based materials. These finishes provide similar performance to traditional repellents while maintaining breathability and softness [14].
The market for plant-based repellents is expected to hit $3.1 billion by 2031, growing at a 9.8% annual rate [15]. North America and Europe are leading this growth, driven by stricter environmental regulations and rising consumer awareness. This natural approach aligns with other PFAS-free technologies shaping the sustainable coatings market by 2025.
sbb-itb-3ba7a4c
4. Sol-Gel Coatings
Sol-gel coatings are emerging as a ceramic-based alternative to PFAS-containing products, offering durability and a reduced environmental impact. These coatings are created by forming a ceramic matrix from small inorganic particles, providing a reliable, non-fluorinated option as manufacturers move away from PFAS-based solutions [19].
Environmental Impact
Compared to PFAS-based coatings, sol-gel coatings have a smaller environmental footprint. Their production emits 50% less carbon dioxide than PTFE coatings [19]. Made primarily from silicon and oxygen, these coatings avoid using harmful fluorinated compounds altogether [19].
Performance Features
Sol-gel coatings deliver impressive performance across several key areas:
| Feature | Specification |
|---|---|
| Surface Hardness | 9H Pencil hardness |
| Coating Thickness | 35 µm ± 5 |
| Heat Resistance | Up to 450°C (842°F) |
| Substrate Compatibility | Aluminum, Stainless Steel, Iron |
Applications Across Industries
Sol-gel coatings are being adopted in various industries due to their versatility and durability. Their market is expanding at nearly twice the rate of traditional coatings [20]. Industries utilizing these coatings include aerospace, automotive, construction, electronics, and healthcare.
A standout example is Pfluon's PDS technology, which has improved non-stick performance by 300% compared to standard ceramic coatings [21]. This advancement highlights the potential of sol-gel coatings to meet eco-friendly demands while maintaining high performance.
Innovations in Manufacturing
The development of sol-gel coatings is advancing through integration with cutting-edge manufacturing techniques. These include 3D printing, robotic applications, self-healing formulations, and the use of bio-based materials [20]. Such innovations make sol-gel coatings an ideal choice for demanding applications like aerospace components, medical devices, and architectural designs, where both durability and environmental considerations are critical [20].
5. Plasma Surface Treatments
Plasma surface treatments provide a PFAS-free way to modify material surfaces at the molecular level. This technology creates water-repellent surfaces without relying on harmful fluorinated compounds, making it a safer option for both people and the planet.
How It Works
Plasma treatment uses synthetic siloxanes to form an ultra-thin, silicone-like coating that's water-repellent. This coating is incredibly thin - only 30 nanometers thick [22] - and penetrates deeply into materials. Treatment times are fast, ranging from just 2 to 120 seconds, depending on the material and component size [23]. This quick and efficient process has applications in a wide range of industries.
Key Performance Features
| Feature | Specification |
|---|---|
| Coating Thickness | 30 nanometers [22] |
| Treatment Time | 2–120 seconds [23] |
| Surface Energy Increase | Up to 96% after 31 days [26] |
| Coating Stability | 8+ months [26] |
Where It's Used
Plasmatreat's Openair-Plasma® technology is already widely used in industries like medical devices, electronics, aerospace, automotive, and textiles [24]. Recent developments have further expanded its potential, making it even more versatile.
New Developments
In November 2024, researchers at Empa (Swiss Federal Laboratories for Materials Science and Technology) introduced a new PFAS-free plasma coating process for textiles. Testing showed that plasma-treated fabrics not only repel water better but also dry faster compared to traditional PFAS-coated materials [22].
"We have even succeeded in permanently impregnating more demanding elastic fibers with the new process, which was previously not possible", said Dirk Hegemann, Ph.D., Researcher [22].
Environmental Advantages
Plasma treatments cut down on chemical solvents, reduce energy use, avoid toxic waste, and have a smaller environmental footprint - all while delivering long-lasting results.
Surface Modification Capabilities
Plasma treatments are highly effective for modifying surfaces in three key ways:
- Surface Cleaning: Removes dust, oils, and organic residues [25].
- Surface Activation: Improves bonding through nanometer-scale etching [25].
- Surface Functionalization: Adds chemical groups to achieve specific properties [25].
These capabilities are especially valuable for industries that demand consistent, high-quality surface treatments while adhering to strict environmental guidelines.
6. Polyurethane Coatings
Polyurethane coatings are stepping up as a strong, eco-conscious alternative in the move away from PFAS-based technologies. Known for their durability and long-lasting performance, these coatings are being widely adopted across industries while addressing environmental concerns.
Waterborne Technology Advancements
Covestro's INSQIN® technology is leading the charge with waterborne polyurethane coatings. These coatings not only provide excellent protection but also significantly lower VOC emissions. Impressively, they achieve over 50% biodegradation within 28 days. Industrial use of this technology has already reduced environmental impact by around 150,000 metric tons annually [27][29].
| Feature | Benefit |
|---|---|
| Water Resistance | Keeps water out while maintaining breathability |
| Lower Emissions | Reduces VOCs and promotes biodegradation |
| Durability | Extends the lifespan of coated products |
Real-World Applications
This technology is thriving in areas like textile production, automotive finishes, and consumer electronics. It delivers water-resistant, durable coatings that meet the high demands of these industries.
Notable Innovations
Covestro has pushed boundaries with its INSQIN® technology, introducing waterborne and partly bio-based polyurethane formulations for textiles.
"In response to tough environmental challenges in the textile coating industry, Covestro has changed the game with the INSQIN® polyurethane technology. These waterborne and partly bio-based or bio-degradable polyurethanes enable our customers to produce textile products with high-performance, durability, soft touch, amazing appearance, and with enhanced sustainability."
– Dr. Torsten Pohl, Head of Global Textile Coatings, Covestro [27]
Key Performance Features
The latest polyurethane coatings offer:
- Enhanced Breathability: Allows moisture to escape while keeping water out
- Versatile Application: Suitable for both thin and thick layers based on needs
- Color Protection: Maintains and improves the appearance of fabrics [28]
These advancements position polyurethane coatings as a practical, environmentally conscious replacement for PFAS-based options, especially in applications that demand both durability and high performance.
7. Non-Fluorine Polymers
Non-fluorine polymers offer water and oil repellency without relying on PFAS. As regulations tighten and industry needs shift, these alternatives are becoming a go-to option for cleaner, PFAS-free technologies.
Recent Developments
In March 2025, AGC Chemicals Americas Inc. (AGCCA) and DRYFIBER LLC introduced a non-fluorinated oil and water repellent designed for nonwoven fabrics and technical textiles. Based on Cornell's polymer chemistry research, this coating creates a microtextured surface that resists oil-based stains and fluids [31].
| Technology Type | Commercial Product | Key Features |
|---|---|---|
| Acrylic Resin | HIGUARD NF-184 | Water and oil repellency for natural and synthetic fibers |
| Bio-Based | OC-aquasil | Stays effective through multiple washes on polyester and polyamide fabrics |
| Nonionic Polymer | NEOSEED NR | Surpasses performance of C6 fluorine-based agents |
Performance Highlights
FibraLAST, launched by AGC in February 2025, showcases several impressive features:
- Withstands temperatures up to 176°F (80°C), meets FDA food contact standards, contains ≤20% active content, and incorporates plant-based materials.
"Our partnership with DRYFIBER marks a significant milestone for AGC Chemicals Americas as we continue to deliver sustainable innovations for the nonwovens and technical textiles market. This development represents a breakthrough in stain-resistant technology, delivering the performance our customers expect without relying on fluorinated chemistries. We are proud to meet the growing demand for non-fluorinated alternatives with this solution."
– Tim Johnson, AGCCA's FibraLAST business manager [31]
Practical Uses
Non-fluorine polymers are being successfully applied in:
- Food Packaging: Protecting against oil and liquid seepage.
- Technical Textiles: Adding long-lasting water resistance.
- Filtration Systems: Maintaining functionality without PFAS.
- Automotive Textiles: Guarding against stains.
- Medical Fabrics: Enhancing fluid resistance.
Environmental Benefits
Traditional PFAS compounds, dominated by four key chemicals (PFOS, PFOA, PTFE, and PFHxS), make up 70% of global PFAS production [30]. Non-fluorine polymers help reduce environmental harm while maintaining essential performance. When combined with other PFAS-free technologies, these polymers can even outperform conventional solutions [30]. This shift highlights the industry's move toward more eco-conscious coatings.
Conclusion
The shift away from PFAS is more than just about meeting regulations - it’s a chance to push boundaries and create better solutions. Many of these alternatives not only match but often outperform PFAS-based options, all while reducing long-term risks to the environment.
A review of 325 applications across 18 industries identified 530 PFAS-free alternatives, with 40 already ready to use and 83 still in development [9]. Here are some standout examples of companies leading the charge:
| Company | Innovation | Impact |
|---|---|---|
| Leclanché | Water-based binder processes | Removed PFAS from LIB cathodes, improving safety for workers |
| Nanoramic Laboratories | 3D nanocarbon binding structure | Created a PFAS-free binder for use in battery applications |
| Hydromer | PFAS-free hydrophilic coatings | Successfully applied these coatings in medical devices |
| Victrex | PEEK polymers | Developed sustainable options for medical applications |
The environmental benefits are clear. Research shows that 40% to 60% of nanocoating uses in consumer goods can switch to PFAS-free alternatives without losing effectiveness [32].
"Eliminating forever chemicals through non-toxic, PFAS-free alternatives is vital for protecting the health of communities and future generations."
– actnano [33]
As global regulations tighten, with expectations that all perfluorinated compounds will be banned under the Stockholm Convention by 2025 [18], manufacturers are accelerating efforts to adopt sustainable solutions.
Dr. Frank Hempel from INP highlights the promise of organosilicon layers, noting their potential for a wide range of industrial uses [18]. This ongoing transformation shows how cutting-edge technology can tackle environmental issues while boosting product performance, paving the way for cleaner, safer manufacturing practices.
