Outdoor and performance textiles often rely on PFAS-based coatings to repel water, dirt and grease. However, these “forever chemicals” persist in the environment and can harm human health. Researchers at the Swiss materials science institute Empa are developing a scalable alternative that could transform how functional textiles are designed.

Towards Safer Functional Materials

Designers use chemical treatments to make clothing weather-resistant. PFAS have long been the industry standard because they perform extremely well. Yet their environmental impact has created an urgent need for safer options.

Empa’s EC0Tex project, developed with Swiss textile manufacturers, focuses on fluorine-free alternatives. The project follows the “Safe and Sustainable by Design” (SSbD) framework. This approach ensures that new materials are safe, effective and responsible. It also helps prevent “regrettable substitutions”, where a replacement causes new problems.

Precision Coating With Plasma Technology

The team has developed a new plasma coating process. Traditional methods often require large amounts of chemicals. In contrast, this technique applies ultra-thin coatings directly to individual fibres.

The process uses an electrically generated plasma. This creates reactive particles that bond to textile fibres. The new system allows these particles to penetrate deep into the yarn. As a result, the coating becomes more even and more durable.

This approach reduces material use while maintaining performance. It also makes the process more resource-efficient. The coated yarns can be used in outdoor clothing, sportswear and technical products such as ropes. This opens up new possibilities for textile and product designers.

Exploring Safer Chemistries

Instead of PFAS, the researchers are testing organosilicon compounds. Early results are promising. These materials form strong, cross-linked coatings. They offer excellent water repellency and dry quickly. In some cases, they even outperform PFAS in durability.

However, challenges remain. Matching the oil and dirt resistance of PFAS is still difficult. This is especially important for protective textiles. The team continues to refine both the materials and the coating process to improve performance.

Implications For Sustainable Design

This innovation supports a shift towards safer and more circular materials. The plasma process uses fewer chemicals and applies them more precisely. This reduces environmental impact without sacrificing functionality.

As regulations on PFAS become stricter, alternatives are essential. Projects like EC0Tex show how material innovation can support this transition. They offer designers new tools to create high-performance products with a lower environmental footprint.

Source & photo: Empa