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Fraunhofer ILT is developing laser-based manufacturing processes for applying PFAS-free functional coatings to metal components, plain bearings, and elastomer rollers. The RePEEK, EPOS, LEMBAS, and pureWaterSeal projects demonstrate that replacing “forever chemicals” requires more than suitable substitute materials. Equally important are the manufacturing processes used to apply them.
Per- and polyfluorinated alkyl substances, PFAS for short, are virtually unbeatable in terms of functionality: They are extremely resistant to both chemicals and heat, and that is precisely why they are facing regulatory pressure. Yet replacing them is far from straightforward. PFAS reduce friction, protect components against wear and corrosion, prevent material build-up, and maintain emergency running properties when lubricating films fail. For these reasons, any alternative requires not only a new material but also a reliable way of applying that material to a wide variety of components.
Through the RePEEK, EPOS, LEMBAS, and pureWaterSeal projects, Fraunhofer ILT is developing laser-based processes for applying PFAS-free high-performance coatings on large metal components, plain bearings, seals, and sensitive elastomer rollers. Depending on the application, the laser can deposit coating materials, melt them locally, or selectively structure the surface. Because it delivers energy precisely where it is needed, and only for a short time, the laser enables engineers to process PFAS-free substitute materials that would otherwise require energy-intensive furnace treatments or temperatures that could damage the underlying component.
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