Fraunhofer’s work marks a significant step toward sustainable, high-performance alternatives in areas where fluoropolymers have long been considered irreplaceable, such as the paints and coatings market.
The Fraunhofer Institutes have launched a new research initiative aimed at replacing fluoropolymers in demanding technical applications in response to growing regulatory pressure on fluorinated substances. The project, titled HATE-FLUOR, began in February and is a collaboration between the Fraunhofer Institute for Structural Durability and System Reliability (LBF) and the Fraunhofer Institute for Manufacturing Technology and Advanced Materials (IFAM).
The initiative comes at a time when manufacturers across industries are seeking alternatives to poly- and perfluorinated alkyl substances (PFAS), also known as ‘forever chemicals.’ These compounds, widely used for their chemical resistance and thermal stability, are facing increasing scrutiny from the European Chemicals Agency (ECHA). Fluoroelastomers, a significant subset of PFAS
used in sealing applications, are among the materials under threat.
The HATE-FLUOR project aims to develop a new generation of high-performance elastomers that are entirely fluorine-free. These materials will be enhanced with tailored antioxidants, novel formulations, and advanced coatings to provide the durability and resistance currently achieved through fluoropolymers.
The project targets a broad range of industries, including mechanical and medical engineering, cleanroom and semiconductor technology, chemical process engineering and electronics, many of which depend on fluoroelastomer components to withstand harsh conditions.
Moreover, Fraunhofer LBF is developing thermally and chemically robust elastomer compounds, focusing on improving thermal and thermo-oxidative stability with cutting-edge antioxidant technologies, as well as creating application-specific formulations to ensure high resistance and strong adhesion. Meanwhile, Fraunhofer IFAM is advancing coating technologies to protect these new elastomers. Key developments include polyimide-based coatings reinforced with layered silicates, designed to block harmful gases and moisture. These coatings are expected to significantly reduce ageing and degradation, especially in sensitive electronics and high-performance environments. Modifications to the layered silicates aim to reduce the permeation of water vapour and oxygen by up to 99%.
The combined expertise of LBF and IFAM in PFAS alternatives and surface technologies underpins the project’s modular approach. By integrating advanced elastomer compounds with plasma and coatings, the HATE-FLUOR initiative promises a scalable and adaptable solution to the looming regulatory and environmental challenges posed by fluorinated materials.