#Research & Development

2025-04-10

High-performance elastomers and plasma polymer coatings to replace fluoropolymers in technical applications: new Fraunhofer project

Users of poly- and perfluorinated alkyl compounds (PFAS), also known as "forever chemicals", are under pressure due to regulatory proposals from the European Chemicals Agency (ECHA). This also affects the use of fluoroelastomers, whose economic significance is enormous. Fraunhofer experts initiated the "HATE-Fluor" project at the beginning of February. Together, they want to develop high-performance elastomer compounds to replace fluoropolymers in certain technical applications.

Kick-off: The Fraunhofer project team and the industry advisory board of "HATE-Fluor" at the first meeting on Tuesday, April 8, 2025 © Fraunhofer IFAM

Various industries can benefit from this, including manufacturers of semi-finished and finished parts as well as companies in mechanical engineering industry, medical engineering, clean room and semiconductor technology, chemical process technology and electrical applications.

Many companies are looking for alternatives to poly- and perfluorinated alkyl compounds (PFAS), as their possible uses in the future are uncertain and voluntary commitments are expected. PFAS are found in everyday products such as coated pans, pizza boxes and outdoor jackets, as well as in medical engineering, heat pumps and batteries. While there are already fluorine-free substitutes for some everyday applications, there is a great need for new individual solutions to replace fluoropolymers for technical applications that have to withstand extreme conditions

PFAS replacement: coated elastomers and customizable modular solutions

In the newly initiated "HATE-Fluor" project, teams of experts at the Fraunhofer Institute for Structural Durability and System Reliability LBF and the Fraunhofer Institute for Manufacturing Technology and Advanced Materials IFAM will develop fluorine-free coated elastomers and offer customizable modular solutions to meet the growing market demand. The solution comprises three main steps: improving the thermal stability of fluorine-free elastomers with novel antioxidants, producing customized elastomer formulations and developing a coating system to protect the elastomer from oxidative and chemical attack.

The modular structure of this system, consisting of paint and plasma coatings, is intended to cover a broad spectrum in the section of fluorine alternative seals. The target properties are determined by the areas of application of the fluoroelastomers that are being replaced in the project.

Bundled Fraunhofer expertise

In the "HATE-Fluor" project, the Fraunhofer Institute for Structural Durability and System Reliability LBF is concentrating on the development of high-performance elastomers as a replacement for fluoropolymers in technical applications. One focus is on improving the thermal and thermo-oxidative stability of fluorine-free elastomers using innovative antioxidants. In addition, application-optimized elastomer formulations are being developed to ensure maximum resistance and optimum adhesion. This is complemented by the formulation of a coating system for the elastomers. The latter is being developed at the Fraunhofer Institute for Manufacturing Technology and Advanced Materials IFAM to protect the material from oxidative attack and chemical degradation.

Fraunhofer IFAM is also working within the project on coatings for these elastomers to improve their friction reduction and barrier properties. A particular focus is on the development of polyimide coatings in combination with layered silicates that prevent the permeation of harmful gases and moisture. These coatings are used in particular for high-performance electronics and other demanding applications. In addition, the modification of the layered silicates is being investigated to reduce the permeation of water vapor and oxygen through the coating by up to 99%. The application of these coatings shows significantly reduced ageing and prevents dendrite growth as a result of exposure to harmful gases.

The Fraunhofer institutes LBF and IFAM are combining their expertise to develop new solutions and application-ready technologies. Both institutes already have extensive expertise in PFAS substitution thanks to many years of development and project work. The "HATE-Fluor" project is funded by the Fraunhofer-Gesellschaft as part of the PREPARE program and will run for three years.

TERIS reaches milestone: Fraunhofer consortium develops new standards for tire analysis

In the “TERIS” project, the Fraunhofer institutes ICT, IGD, and IWM—led by the Fraunhofer Institute for Structural Durability and System Reliability LBF—have reached a decisive milestone. For the first time, the teams aim to generate, analyse, and predict tire wear in the laboratory in a standardized and practical manner. As part of this milestone, results are now available on reference abrasion, particle analysis, tribological models, AI-based surface analysis, a test bench concept, and methods for accelerated aging and VOC detection. The tire industry, testing services, and environmental agencies will in future benefit from reliable, rapid laboratory procedures for emissions assessment.

Bio-based polyesters for challenging long-term applications

Current bio-based plastics are often only suitable for short-lived applications, such as packaging, because they have inadequate long-term properties. The new project “Bio-based polyesters for challenging long-term applications” from the Fraunhofer Institute for Structural Durability and System Reliability LBF aims to improve the long-term properties of bioplastics through targeted additivation in order to enable their use in technical applications. To do this, the researchers are looking for companies along the value chain that would also like to substitute petro-based plastics with bio-based solutions in long-lasting products.

ADD-ITC 2026 publishes preliminary conference program

The organizers of the Aachen-Dresden-Denkendorf International Textile Conference (ADD-ITC) 2026 have released the preliminary program for this year's event, which will take place on November 26–27, 2026, at the International Congress Center Dresden. The conference is expected to attract between 500 and 700 participants from industry, research, and academia.

Networking Day 2026: Industry stakeholders unite around textile recycling

In 2026, the Industry Research Group (IRG) Polymer Recycling once again brought together some of the key stakeholders in textile recycling for its annual Networking Day. This year, the event took place at EREMA’s premises in Ansfelden, Austria. It brought together key players from across the textile recycling value chain for a day of structured exchange and in-depth discussions.

Smart textiles reversibly change shape in an energy-efficient manner in response to ambient temperature

Self-actuating textile structures are used in a wide range of applications, such as medical technology, automation, architecture, agriculture, and the apparel industry. An example is the use of shading nets in greenhouses, which can be deployed and retracted depending on the sunlight intensity. The German Institutes of Textile and Fiber Research Denkendorf (DITF) are developing textiles based on shape-memory polymers with reversibly controllable geometry.

Meadow Grove Research joins ITMF as Corporate Member

Meadow Grove Research is a commodity research firm specializing in supply, demand, and trade analysis in cotton and other soft commodities. Providing clarity to the complex nature of the global fiber supply chain is one of its most formidable services. The firm thrives on customer engagement and providing the best framework for critical decisions.

SHIMA SEIKI brings new flat knitting technologies to FEBRATEX 2026

Leading flat knitting solutions provider SHIMA SEIKI MFG., LTD. of Wakayama, Japan, together with its Brazilian representative BRASTEMA TECNOLOGIA TEXTIL LTDA., will exhibit at the Brazilian Textile Industry Fair (FEBRATEX 2026) this month. On display will be a roundup of SHIMA SEIKI computerized flat knitting technology, represented by WHOLEGARMENT® knitting machines, computerized flat knitting machines featuring a brand-new model with high productivity and excellent cost performance, a glove knitting machine and the latest digital solutions.

Lenzing reports improved half-year results and advances strategic transformation

Despite a persistently challenging market environment in the first half of 2026, characterized by volatile energy and raw material prices, subdued global consumer demand and intensified competition from Asia, the Lenzing Group significantly improved its financial performance. Net result after tax more than doubled to EUR 35.6 million, compared with EUR 15.2 million in the first half of 2025. Free cash flow increased to EUR 45.8 million, while EBITDA amounted to EUR 239.2 million. Revenue totaled EUR 1.27 billion, compared with EUR 1.34 billion in the previous year.

Trützschler’s latest spinning and card clothing innovations at CAITME 2026

From September 8 to 10, 2026, Trützschler will present its latest innovations in spinning and card clothing for state-of-the-art fiber processing at CAITME in Tashkent, Uzbekistan. Visitors are invited to meet the experts at Pavilion 2, Booth D50 and explore solutions designed to increase productivity, streamline processes, and ensure consistently high yarn quality. Key topics include the next-generation card TC 30i, the integrated draw frame IDF 3, the high-performance comber TCO 21XL as well as Trützschler Card Clothing’s new flat top series STEELTOP®.