The application of electrodeposition processes for providing porous structures such as foams, fiber cloths or packed fiber beds with a metallic coating remains a challenging process, since the throwing power of these processes into the porous structure is in general very poor. In this presentation, it will be demonstrated by simulations for an acid copper deposition process that the deposit thickness decreases very rapidly when progressing further into a fiber cloth structure. The simulated results were obtained from a FEM based Multi-Ion Transport and Reaction (MITRe) model with transport and kinetic electrode reaction parameters that are relevant to an acid copper deposition process. The same MITRe model is used for investigating different mitigation strategies aiming at an enhanced throwing power in the fiber cloth structure. It is demonstrated that a carefully defined forced electrolyte flow system and the application of pulse current programs can largely enhance the throwing power.

The EU-funded MOZART project investigates nickel-based dispersion coatings incorporating nanoparticles as a viable alternative to hard chrome. This Mixed Metal Composite (MMC) approach has already demonstrated excellent mechanical properties, achieving hardness values up to 1000 HV.

Because nanoparticles do not undergo electrochemical discharge at the cathode, conventional electroplating models cannot predict their incorporation into the deposit. A major challenge lies in nanoparticle agglomeration, which can lead to precipitation and uneven distribution within the coating, particularly across surfaces with varying orientations. To address this, electrochemical characterization of plating bath chemistries is performed under different geometric conditions. These insights, combined with Computer-Aided Engineering (CAE) tools, enable prediction of particle content within the nickel matrix across complex component surfaces.

This contribution presents the integration of electroplating simulations with particle co-deposition modeling and highlights the design of plating tooling for multiple demonstrator parts. The proposed methodology establishes a framework for developing tailored tooling solutions, supporting the adoption of MMC coatings as a sustainable replacement for hard chrome.

Offshore wind turbine blades are significantly affected by rain erosion, particulate impacts, and biofouling, leading to surface degradation, increased aerodynamic drag, and higher maintenance costs, thereby hindering wind energy decarbonisation goals. Addressing this challenge requires developing coating solutions that offer improved resistance to wear and biofouling, manufactured through eco-friendly, energy-efficient processes. The study introduces silica‑based hybrid sol‑gel coatings reinforced with metallic and carbon nanoparticles, providing a sustainable route to the creation of mechanically robust, hydrophobic surfaces for glass‑fiber reinforced polymer (GFRP) wind turbine blades.

Tetraethylorthosilicate (TEOS) based sol-gel formulations containing 0.1wt% commercially available silver nanoparticles (AgNPs) and multi-walled carbon nanotubes (MWCNTs) were synthesised, applied to GFRP substrates via dip-coating, and thermally cured at 120°C for 2 hours.

Material characterisation confirmed that the MWCNT-enhanced sol-gel coatings exhibited higher mechanical, thermal, and surface properties compared to the AgNPs formulation. Attenuated Total Reflectance Fourier Transform Infrared (ATR-FTIR) spectroscopy analysis confirmed strong Si-O-Si network formation, with MWCNTs creating a denser structure. Water contact angle (WCA) measurements confirmed an increase in hydrophobicity with the addition of MWCNTs, effectively controlling surface energy. The TGA results showed improved thermal stability of MWCNT coatings, with lower mass loss compared to AgNPs coatings. Differential scanning calorimetry (DSC) confirmed thermal stability up to 300°C for both formulations.

Nanoindentation showed significant mechanical enhancement, with MWCNT-reinforced coatings exhibiting 26% higher hardness (0.400 vs. 0.318 GPa), a higher elastic modulus (3.24 GPa), and reduced indentation depth, indicating superior load-bearing capacity and deformation resistance. Furthermore, a preliminary droplet impact erosion test (DIEM) was performed for short periods to evaluate resistance to rain impact. Additionally, antimicrobial activity was assessed as an initial indicator of anti-fouling potential.

The study demonstrates that carbon-based nanomaterials outperform metallic nanoparticles in producing durable, hydrophobic coatings for renewable energy applications.

Per- and polyfluoroalkyl substances (PFAS) are widely used for their water and oil-repellent properties in various applications, including textiles, packaging, cookware, medical applications, electronics, etc. However, their persistence and toxicity present significant environmental and health challenges. The Horizon Europe BIO-SUSHY project aims to develop innovative coating solutions that align with the EU’s chemical strategy for sustainability, targeting a toxic-free environment.

BIO-SUSHY’s approach is built on three pillars: (i) research and innovation in hybrid organic/inorganic coating formulations, (ii) computational modelling to optimise performance and safety, and (iii) integration of the Safe and Sustainable by Design (SSbD) methodology. The developed solutions are validated in three strategic markets: textiles, food packaging, and cosmetic packaging.

Among the case studies, the application of sol-gel coatings to cosmetic glass containers demonstrates reduced waste (up to 25%), facilitates container reuse, and ensures user safety while meeting regulatory requirements. As part of its work on these coatings, BIO-SUSHY invests considerable efforts in implementing the Safe-and-Sustainable-by-Design (SSbD) framework, integrating sustainability strategies such as circularity and eco-design principles. Key to this approach is a multidisciplinary methodology based on computational tools and data-driven modelling, coupled with rapid release and screening technology, all embedded within a life cycle thinking perspective. In this way, the principles of SSbD are applied to organic and hybrid coating formulations to ensure that, from an early stage of the innovation process, both safety concerns and sustainability criteria are addressed so that more safe and sustainable value chains can be established.

This presentation aims at providing an overview of the project concept, methodology and main outcomes in BIO-SUSHY case studies.

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.

Data-driven AI, based on Machine Learning (ML) methods, can be used for High Entropy Alloys (HEAs) coatings’ modelling and quality prediction. Using experimental or historical data concerning HEAs coatings’ processes & materials, ML can be useful in cases that physics-based models do not exist, are not adequate or are not efficient e.g. due to new composition of alloys, new coatings processes’ parameters, multi-scale modeling, stochastic factors that influence quality, etc. Using ML methods, including Artificial Neural Networks (ANNs), Classification and Regression methods, ML models can be created to predict alloys’ structure (e.g. crystal structure) & coatings properties (e.g. hardness) and for several alloy compositions and temperatures. This ML modeling approach is being applied within the Horizon Europe project M2DESCO, and several ML methods & training algorithms have already been used and tested within the project with satisfactory results, including the Feed-Forward Multilayer Perceptron (FF-MLP) ANN using the Backpropagation training algorithm, and ML Classifiers, like the LBFGS Maximum Entropy Multiclass Classifier and the Light Gradient Boosting Machine (LightGBM) Classifier. Especially the LightGBM multiclass classifier provided the best alloys’ properties prediction results for 2 of the alloys used in the project, which were the Co-Cr-Fe-Mo-Ni and Al-Cr-Mo-Ti-W alloys, and for several compositions (molar fractions) of these alloys.

Biofouling and surface contamination on turbine blades can substantially increase aerodynamic drag, which reduces efficiency and accelerates corrosion-driven material degradation. To address these challenges, biomimetic coatings have been heavily experimentally researched as passive mitigation surface treatments. The use of superhydrophobic (SHB) and superhydrophilic (SHL) biomimetic coatings reduces the adhesion of fouling organisms and is considered to provide antifouling, anti-icing, anti-corrosion, and self-cleaning properties.

Although extensive state-of-the-art analyses of these surface textures have yielded volumes of data, this data is disconnected and lacks the coherency needed to identify, design and optimise an effective surface technology. This is due to the lack of informed selection data of texture morphologies and densities, which is due to the lack of related simulation studies. As a result, most experimental studies randomly select and test texture morphologies without understanding how specific structural features influence biological and mechanical surface degradation phenomena.

This paper presents a study on the interfacial influence of various biomimetic surface morphologies and densities on water droplet impacts. Three different morphologies with different interpillar distances were simulated to create either SHB or SHL surfaces on Ansys Fluent. Results indicated that morphologies influence the maximum pressure and maximum spreading diameter of the impacting droplet. Phase 2 of this study will provide preliminary data on morphology-design optimisation. Seven parameters were evaluated using one-factor-at-a-time sensitivity analysis. In this stage, coupled level-set and VOF method was used and the results showed in SHB textured surfaces the impact velocity and droplet diameter strongly influence the outcomes. For SHL surface designs, the ambient temperature had the largest effect on the outcomes and showed more nonlinear relationships. Due to the nonlinear effect, further factorial analyses will use a design of experiments (DOE) approach, such as the Box-Behnken method, to investigate the selective/collective synergistic/antagonistic influences of the selected parameters.

Ice formation on exposed surfaces remains a critical challenge for infrastructure operating in cold environments, where conventional passive anti-icing coatings often suffer from limited effectiveness and durability. This work presents a multilayer coating strategy that integrates aqueous self-lubricating surface chemistry with an underlying phase change material (PCM)-containing layer to achieve enhanced, synergistic anti-icing performance.

The top layer consists of a PEG-PDMS copolymer-modified coating that forms a quasi-liquid-like (QLL) interfacial water layer, as directly confirmed by solid-state NMR spectroscopy. The presence of this viscous interfacial layer delays ice nucleation and significantly reduces ice adhesion by limiting molecular mobility at the ice–coating interface. Differential scanning calorimetry further demonstrated that this interfacial lubrication mechanism lowers the ice nucleation temperature through viscosity-driven kinetic effects. Encapsulated PCMs were selected to release latent heat within the critical temperature range associated with glaze ice formation. Infrared thermography demonstrated that PCM-containing samples maintained higher surface temperatures during cooling from 0 to −20 °C, effectively prolonging the lifetime of the QLL. As a result, the complete freezing time increased dramatically from approximately 190 s for PDMS to up to 1560 s for coatings containing 50 wt.% PCM.

Ice adhesion measurements showed a substantial reduction for PEG-PDMS coatings compared to PDMS references, with a further decrease observed when the PCM layer was incorporated. Static-accumulation tests conducted at −5 °C confirmed a significant reduction in ice accretion for the multilayer system compared to single-layer coatings. Importantly, positioning the PCM beneath the self-lubricating layer preserved mechanical integrity while mitigating PCM depletion, enabling higher PCM loading without compromising coating durability.

This multilayer design demonstrates how thermal energy storage and interfacial lubrication can be combined effectively to overcome the limitations of individual anti-icing strategies, offering a robust, scalable pathway for next-generation passive icephobic coatings.

In this work, we present an optimisation-based decision support framework developed within the PROPLANET project, aimed at assisting potential users of the PROPLANET Replication Tool in the design and assessment of sustainable by design (SSBD) coatings production processes.

According to the information obtained with simple box for planet (SB4P) two multiobjective optimisation models have been formulated to simultaneously maximise coating production volume and minimise pollutant emissions generated along the production chain across different environmental media, including air, water, and soil. The model explicitly accounts for the final performance and quality properties of the coatings, ensuring that sustainability improvements are achieved without compromising functional requirements.

To approximate the Pareto front of the formulated problem, multiobjective metaheuristic optimisation techniques have been applied, specifically the Non-dominated Sorting Genetic Algorithm II (NSGA-II). The resulting set of solutions provides decision-makers with a structured overview of feasible compromises, enabling informed choices depending on production goals and environmental constraints.

The proposed approach demonstrates how multiobjective optimisation and simulation-based methods can effectively support decision-making in the development of sustainable industrial coatings, highlighting the potential of evolutionary optimisation tools to accelerate the transition towards environmentally responsible manufacturing processes.

The pervasive use of per‑ and poly‑fluoroalkyl substances (PFAS) in non‑stick, anti‑soiling and water‑repellent coatings has generated growing concerns over their toxicity, persistence and bio‑accumulation. In response, the TORNADO and PROPLANET projects have pursued sol‑gel‑based, PFAS‑free hybrid coatings that simultaneously meet the demanding functional, mechanical and aesthetic requirements of kitchenware, low‑maintenance glass and food‑packaging machinery.

In the TORNADO line, a ceramic–organic network is generated by hydrolysis and condensation of metal alkoxides combined with siloxane organofunctional groups and silicon oils. Optimised precursor ratios yield a two‑layer system (base‑coat + top‑coat) that can be sprayed onto aluminium pans. The resulting film is homogeneous, hydro‑ and oleo‑phobic (SFE ≈ 25 mN/m), scratch‑, impact‑ and abrasion‑resistant, corrosion‑proof and stable at cooking temperatures up to 300 °C.

Parallel work in PROPLANET has produced two sol‑gel‑based families of coatings. (i) Transparent hybrid films for glass provide durable hydrophobic and anti‑soiling performance, suitable for automotive windows and shower doors. (ii) PFAS‑free, functionalised hybrids for food‑packaging machines deliver non‑stick, anti‑wear behaviour together with high‑temperature resilience. Systematic screening of chemistries and functional groups, together with contact‑angle measurements (water/hexadecane) and standard mechanical tests, confirms omniphobic surface free energies and long‑term durability under service‑relevant conditions.

These results demonstrate that sol‑gel chemistry enables the design of environmentally benign, high‑performance coatings, offering a viable pathway to replace PFAS in diverse consumer and industrial applications while supporting circular‑economy value chains.

Abstract

Ice accumulation on engineering surfaces operating in cold environments presents persistent safety, performance, and economic challenges across sectors such as aerospace, wind energy, transportation, and power infrastructure. Conventional de-icing strategies, including mechanical removal, chemical agents, and resistive heating, are often energy-intensive, costly, and environmentally harmful. In this context, polyurethane (PU)-based photothermal coatings offer a promising alternative by combining mechanical durability, environmental compatibility, and multifunctional ice-mitigation capability.

This study presents a simple and scalable strategy to develop multifunctional PU coatings with enhanced anti-icing and de-icing performance through the incorporation of iron oxide (Fe₃O₄) nanoparticles with tailored surface chemistry. Three nanoparticle systems were investigated: unmodified Fe₃O₄ (FPU), silicone oil–coated Fe₃O₄ (SiFPU), and hydroxyl-functionalized Fe₃O₄ (FOHPU), with loadings ranging from 0.5 to 10 wt%. The influence of nanoparticle functionalization on mechanical integrity, photothermal conversion efficiency, and icephobic behavior was systematically evaluated.

The coatings were fabricated and characterized using scanning electron microscopy (SEM), Fourier-transform infrared spectroscopy (FTIR), UV–Vis spectroscopy, and tensile testing. Photothermal performance was quantified via infrared thermography under 1-sun xenon illumination. Icephobic behavior was assessed using ice push-off tests conducted in a controlled cold-room environment, both with and without simulated solar irradiation. Coating durability was evaluated through repeated icing/de-icing cycles to assess long-term performance stability.

UV–Vis spectroscopy revealed significantly enhanced light absorption in nanoparticle-modified coatings, with silicone oil coating and hydroxyl functionalization reducing the Fe₃O₄ band gap by 2.3 and 2.55 eV, respectively. Surface-functionalized nanoparticles markedly improved icephobic performance. The 10FOHPU coating exhibited superior mechanical properties, achieving a Young’s modulus of 140 ± 6.2 MPa and a tensile strength of 6.3 ± 0.2 MPa, compared to 106.1 ± 4.1 MPa and 6.1 ± 0.4 MPa for pristine PU. ATR-FTIR analysis at sub-zero temperatures confirmed the formation of a quasi-liquid interfacial layer on FOHPU coatings. Notably, the 10SiFPU coating demonstrated the lowest ice adhesion strength (40 ± 8 kPa) after 20 minutes of light exposure. These results demonstrate that tailoring nanoparticle surface chemistry within PU matrices enables a synergistic enhancement of mechanical robustness, photothermal efficiency, and icephobic performance, offering a sustainable and energy-efficient solution for advanced ice-mitigation applications.