The BIO-SUSHY project is developing PFAS-free, bio-based coatings that potentially address a portion of the expanding EUR 1.5 billion PFAS-free coatings market and significant environmental challenges. Companies that adopt PFAS-free coatings mitigate compliance risks, expand their market presence, and enhance their brand reputation. On the other hand, companies that persist in using PFAS face potential fines and restricted market access due to increasingly stringent regulations.

BIO-SUSHY coatings are aligned with evolving regulatory requirements and increasing consumer demand for sustainable products. In fact, the project implements Safe-and-Sustainable-by-Design (SSbD) principles, initially demonstrating applications for textiles, paper food trays, and cosmetic glass packaging, with potential for broader industry adoption. The PFAS-free coatings market is forecasted to grow from EUR 1.5 billion in 2024 to EUR 2.1 billion by 2030. Key markets include Europe (35-40% share, led by REACH), North America (with state-level PFAS bans), and Asia-Pacific (the fastest-growing region, accounting for 40% of the food packaging market).

The main BIO-SUSHY innovative coatings are thermoplastic powder coatings (80-98% bio-based) for food packaging, where regulatory bans in the EU and US, as well as corporate commitments from quick-service restaurants (QSR), are increasing demand. Hybrid organic and inorganic sol-gel coatings (23-46% and 5-15% bio-based, respectively) are developed for technical textiles and glass cosmetic packaging.

Key success factors include demonstration at Technology Readiness Level 6 (TRL6), intellectual property rights (IPR) protection, comprehensive SSbD documentation, and a standardization roadmap that lowers market entry barriers, positioning SSbD-validated coatings as preferred alternatives in markets where regulations are phasing out persistent pollutants.

The BIO-SUSHY project is funded by the European Union under the Grant Agreement Number 101091464. Views and opinions expressed are however those of the author(s) only and do not necessarily reflect those of the European Union or the European Health and Digital Executive Agency (HaDEA). Neither the European Union nor the granting authority can be held responsible for them.

Coating solutions containing chemicals are frequently employed in many surface finishing industries even though they do not adhere to regulations encouraging safer and more sustainable options. Hard Chromium (HC) coatings are extensively used in multiple sectors such as manufacturing, automotive and machinery fields because of their outstanding mechanical and wear characteristics yet they remain hazardous. To address this challenge the EU-supported MOZART project creates coating technologies offering safe and eco-friendly substitutes for HC delivering the same or better performance while removing harmful chemicals and minimizing environmental harm.

Within this framework Safe and Sustainable, by Design (SSbD) methods are implemented. SSbD provides a structure addressing chemical safety, performance, recyclability and overall product sustainability. To convey the insights developed during the project to the target audience we introduce the MOZART Decision Support Tool (DST) a platform that helps users assess and choose sustainable coating options. The DST integrates SSbD. Delivers detailed data, on materials, coating characteristics, LCA, LCC and toxicity effects.

By means of scenario-based evaluations the tool facilitates the comparison of nickel-based options with MOZART-derived coatings intended to substitute HC. Results feature sustainability ratings, risk metrics and comparative analyses that assist stakeholders in making informed substitution choices consistent, with EU sustainability objectives.

The overall aim of the DST is to facilitate end users in defining SSbD-compliant alternatives, enabling rapid and economically feasible adoption by plating SMEs and large manufacturers.

Funded by the European Union under the GA no 101058450. Views and opinions expressed are however those of the author(s) only and do not necessarily reflect those of the European Union or RIA. Neither the European Union nor the granting authority can be held responsible for them.

In a context of climate crisis, hydrogen technology emerges as a key factor, offering a clean fuel with a high energy density which can be produced through water electrolysis. However, the widespread usage of hydrogen as an energy vector is hindered by a significant bottleneck: most electrodes contain platinum group metals (PGMs) due to their high catalytic activity and stability. Such PGMs are scarce and costly and prevent the use of hydrogen and fuel cells on a larger scale. In this context, the NICKEFFECT project aims to develop novel (i) Ni-based coating materials to replace PGMs and ensure high efficiency in key applications such as fuel cells, and (ii) Ni-based ferromagnetic systems for random-access memory applications.

In this work, we present how active learning has been successfully applied to reach optimal catalytic performances of Ni-W dense coatings by tuning the deposition parameters [1]. Additionally, we show how density-functional theory and machine-learned force fields have been used to provide a better understanding of the magneto-ionic properties of Ni-Co oxide patterned microdisks [2].

This work is funded by the European Union. Views and opinions expressed are however those of the author(s) only and do not necessarily reflect those of the European Union or the European Health and Digital Executive Agency (HaDEA). Neither the European Union nor the granting authority can be held responsible for them.

[1] R. de Paz-Castany et al., ChemSusChem 18, e202400444 (2025)

[2] A. Arredondo-López et al., ACS Applied Materials & Interfaces 17, 9500-9513 (2025)

The use of standardisation in research and innovation projects aims to increase the impact and significance of the results obtained by including them in new standards. By translating validated research outcomes into pre-normative and normative documents, standardization facilitates reproducibility, comparability, and industrial uptake of emerging technologies, while supporting regulatory alignment and risk-informed decision-making. This is in line with the European Policy on Knowledge Valorisation and the ERA Code of Practice on Standardisation, which recommend using tools such as standardisation, among others, to make research results benefit economic activity, welfare and safety in Europe.

Within this context, the NICKEFFECT project integrates standardization as a strategic activity to maximize the impact of its scientific results in the field of non-noble metal-based coatings and electrodes for hydrogen generation. The involvement of UNE (Spanish Association for Standardization) a leading European standardization body with extensive experience in R&I projects, enabled the systematic identification and prioritization of project outputs with high standardization potential. Several pre-normative topics were evaluated, leading to the selection of the most industrially relevant topic as the technical basis for a CEN-CENELEC Workshop Agreement (CWA).

The resulting CWA 18302, “Electrochemical characterisation at laboratory scale of non-noble porous metal-based electrodes for hydrogen generation in acidic medium”, developed under the technical leadership of CIDETEC, provides harmonized recommendations for laboratory-scale electrochemical characterization. The work addresses key methodological aspects relevant to porous metal coatings, including test conditions, performance metrics, and data reporting, with particular attention to durability, activity, and reproducibility. By establishing a common characterization framework, the CWA supports SSbD principles by enabling consistent assessment of performance-sustainability trade-offs and facilitating comparability across research and industrial laboratories and integration of the research data into the decision support tools.

This contribution demonstrates how standardization can act as an effective bridge between advanced materials research, SSbD objectives, and industrial implementation, particularly for emerging coating technologies aimed at sustainable hydrogen production.

The development of platinum group metal free (PGM-free) electrocatalysts is essential to progress towards affordable oxygen reduction reaction (ORR). In this work, Ni-W nanoparticles (NPs) were electrodeposited on carbon cloth (CC) under both direct current and pulsed conditions from a gluconate-based electrolyte [1]. Machine learning (ML) was employed to identify the optimal deposition parameters for enhancing ORR performance in alkaline medium. The variables tuned during NP synthesis included temperature, overpotential, deposition time, and the rotation speed of the electrode, the latter controlled using a rotating disk electrode (RDE) to regulate mass transport.

For the electrochemical characterization, 200 cyclic voltammetries were performed in 0.1 M KOH on a three-electrode cell configuration with a RDE as the working electrode. The key parameters used to evaluate the catalytic activity and durability of the NPs were the half-wave potential and overpotential, both measured at the first and last cycles.

The morphology of the deposited NPs was examined by SEM to determine particle distribution across the CC substrate and particle size, which ranged from 40 nm to 600 nm depending on the deposition conditions. High-resolution (S)TEM imaging was conducted to elucidate the crystal structure and atomic distribution of Ni and W within the NPs. The analysis revealed that W preferentially accumulates towards the surface of the NPs, a feature that contributes to enhanced stability during ORR.

This work is funded by the European Union. Views and opinions expressed are however those of the author(s) only and do not necessarily reflect those of the European Union or the European Health and Digital Executive Agency (HaDEA). Neither the European Union nor the granting authority can be held responsible for them.

[1] R. de Paz-Castany et al. ChemSusChem 18 (2025) e202400444.

Platinum (Pt) has unique chemical and catalytic properties, making it indispensable for several key industrial applications, such as Renewable Energy or Electric Mobility. However, due to its high price and scarcity, reliance on import from sources outside Europe, and lack of effective substitutes for Pt, it is categorized as a Critical Raw Material (CRM). To address this, several attempts have been made to (partially) replace Pt with more inexpensive and abundant metals, such as Iron, Molybdenum or Cobalt. Nevertheless, prevous reports on Pt substitution often focus only on the catalyst’s properties during optimization at the laboratory scale, while criteria of Safety and Sustainability are often overlooked.

According to the Safe and Sustainable by Design (SSbD) framework, safety and sustainability considerations should be integrated into the early stages of development for new materials, by iteratively applying the assessment phase and the re-design phase of the framework at each scale of development. Specific operations or substances can be identified as hotspots during the assessment phase at early stages of development, and targeted for substitution / minimization during the re-design phase, before technology lock-ins occur.

Previous sustainability assessments have revealed that the Pt catalyst in Membrane Fuel Cells (MFCs) is a major contributor to the environmental impacts. Here, the (partial) substitution of Pt by Nickel-based coatings is addressed, as a cathode catalyst for MFC applications. Core-shell nanoparticles are prepared with a range of Pt loadings between 0.01-0.2 mg/cm² and tested as catalysts for oxygen reduction reaction in acidic conditions typical for MFC. A comparative Life Cycle Assessment (LCA) and Chemical Risk Assessment (CRA) of different catalyst compositions with varying Pt content is performed, to establish a correlation between the catalyst performance, safety and sustainability criteria, and quantify the trade-off between the catalyst performance and sustainability when increasing Pt loading. The outcomes of the assessments are used to select an optimal Pt content for upscaling and characterization at the demonstrator scale. Finally, the outcomes are used to establish Re-Design indicators and SSbD Criteria for CRM substitution, which can contribute to SSbD assessments on MFC applications beyond the pilot scale.

Funded by the European Union under Grant Agreement No. 101058076. Views and opinions expressed are however those of the author(s) only and not necessarily reflect those of the European Union or HADEA. Neither the European Union nor HADEA can be held responsible for them.

Efficient thin film deposition by PVD can be challenging in numerous situations like complex-shaped objects or systems of multiples objects in competition due to shadowing. As an example, we can think about deposition of hard coating on cutting tools.

In this work, we are investigating thin films deposited by magnetron sputtering process on drill bits placed on a holder in motion. The aim is to show if and how the conformality of such coating can be obtained with such process.

The deposition process is modelled by combining Computational Fluid Dynamic (CFD), Monte-Carlo algorithm and ray-tracing (using the software Virtual Coater) to be able to predict the fluxes deposited on the meshed 3D objects. This modelling tool is coupled to an atomic scale kinetic Monte-Carlo model to simulate the time dependent growth of the film at different positions of the samples. A special attention is paid to the influence the kind of motion or the number of pieces in the chamber on the conformality of the coating.

This approach allows to reduce substantially the R&D time which is necessary to find optimal process parameters. Moreover, such modelling workflow can be extended to any study implying PVD deposition on large number of objects in motion, like in e.g. hard coating on ball bearing for medical applications, or coating of micron-scale particles in the domain of battery.

This study investigates the microstructure and the mechanical performance of Mo, W and Cr doped AlTiN coatings. The coatings have been produced by magnetron sputtering, a waste-free thin film production technology. It will be discussed whether the Mo and W containing AlTiN based coatings could be qualified as medium/high-entropy nitrides as the dominant phase is a solid solution. In this frame, the research is part of the Horizon Europe project M2DESCO (grant agreement 101138397), aimed to develop novel computational models for the design of safe & sustainable high-entropy coatings. The ultimate goal is to achieve coatings which allow the lifespan_enhancement of machining tools by 50%, which would substantially reduce the consumption of raw materials used in these items.

The coatings have been deposited on high-speed steel AISI-M2 (60 HRC) by co-sputtering a Al₃₃Ti₆₇ target in DC_pulsed mode with a Mo or a dual-tile Mo/W or Mo/Cr target in HIPIMS mode, thus obtaining TiAlMoN, TiAlMoWN and TiAlMoCrN coatings respectively. The coating series presented in this study were prepared for different HIPIMS power, while keeping constant the DC sputtering power over the AlTi target. In addition, the influence of the N₂ mass flow has also been investigated. The adhesion of the films was optimized with a combination of Ti and TiN cladding layers.

The effect of the Mo, Mo/W and Mo/Cr co-sputtering, and the N₂ mass flow significantly affects the structure and hardness of the coatings. The dominant face-center-cubic (FCC) structure of the Mo-free AlTiN is also affected upon the increase of the Mo, Mo/W and Mo/Cr sputtering powers, as reflected in notable changes in the crystallite domain sizes and the cell lattice parameters, while the indentation hardness of the coatings notably increases. In addition, the sputtering of dual-tile Mo/W target leads to even higher hardnesses over these of the TiAlMoN coatings.

In the civil and industrial fields, precise control of process parameters is a fundamental requirement to ensure safety and reliability. Sensor technologies provide a wide range of solutions for monitoring chemical and physical quantities. Owing to their immunity to electromagnetic interference, mechanical robustness, and small dimensions, optical fiber sensors—particularly Fiber Bragg Gratings (FBGs)—enable the monitoring of parameters such as temperature and strain even under harsh environmental conditions, ranging from cryogenic temperatures to values exceeding 1000 °C. A crucial aspect of optical fiber performance is related to external coatings, which directly influence mechanical behavior, durability, and compatibility with specific applications. Commercial optical fibers are typically coated with a polymeric layer that provides mechanical protection and facilitates handling. In this work, a nanostructured silver-based metallic coating is deposited via a bottom-up chemical process involving a redox reaction between silver nitrate (AgNO₃) and glucose solutions; its morphological characteristics are investigated. Depositions are performed on bare optical fibers and on fibers coated with polymeric materials, including acrylate, polyimide, and Ormocer®. Through the optimization of process parameters—including pH, temperature, deposition time, and coating thickness—and the study of surface chemical compatibility, the quality of the metallic layers is evaluated for adhesion, uniformity, and homogeneity. The novelty of this work lies in the optimization of a metal deposition approach that is rarely reported for optical fiber coatings. Its application to polymer-coated fibers requires addressing substrates with tailored thermal and chemical resistance, prompting a thorough evaluation of their physicochemical properties to ensure effective metal adhesion and compatibility. Overall, this study contributes to the scientific literature by assessing the potential direct applicability of this method to FBG sensors and by providing a solid foundation for future investigations into sensor performance and the enhancement of measurement capabilities.

Zinc oxide (ZnO) thin films are the subject of extensive investigation because of their outstanding physical characteristics that make ZnO thin films highly suitable for a broad range of applications such as optoelectronic systems, transparent electronic devices, gas sensing technologies, solar energy conversion, and biosensing platforms.

The performance of ZnO-based thin films is closely influenced by the selected deposition methods and the specific conditions under which the films are grown. Various methods have been developed for the deposition of ZnO thin films, among which electrospray has emerged as a versatile and scalable technique that enables tunable film properties through straightforward variation of deposition parameters. One particularly important parameter is the substrate temperature, which governs droplet mobility on the substrate surface and significantly influences film morphology and crystallinity.

In the present study, ZnO thin films were deposited by electrospraying at relatively low substrate temperatures ranging from 120 °C to 150 °C. The surface morphology, roughness, crystallinity, water contact angle, and film thickness were systematically investigated, and their dependence on substrate temperature was analyzed. The potential application of the films as ammonia gas sensors was evaluated using the quartz crystal microbalance (QCM) method, for which the films were deposited onto quartz crystal resonators and their frequency responses were monitored during ammonia exposure.

The results demonstrate that the properties of ZnO thin films can be effectively tuned by adjusting the substrate temperature, enabling optimization for gas-sensing applications.

Acknowledgement

The support of the Bulgarian National Science Fund Project KP-06-COST/29 (2024) and COST action CA21159 are highly appreciated. Research equipment of Distributed Research Infrastructure INFRAMAT, part of Bulgarian National Roadmap for Research Infrastructures, supported by Bulgarian Ministry of Education and Science was used in this investigation.