In recent years there has been an active shift from conventional Hard Chromium plating to advanced protective coatings in the European plating industry. These coatings present suitable properties in order to be applied on gears improving their performance and complying with environmental standards. This study evaluates the financial feasibility of two emerging coating technologies utilizing SiC150 and Graphene through a detailed cost and cash flow analysis.

Firstly, unit costs were calculated for all stages of the coating process, including material, energy, equipment, labour, and overhead costs. For a standard gear, per-gear costs were determined for both SiC150 and Graphene coatings. When scaling up to batch production and considering the base gear costs, the analysis resulted in total production costs in which Graphene showed a slight cost advantage. Based on industrial-scale projections conducted at a later stage, the scalability and cost efficiency of both coatings were confirmed.

Finally, a cash flow analysis over ten years was calculated, incorporating expected sales growth, operating expenses, and an industrially relevant gross margin. Based on the analysis a positive cumulative cash flow is achieved from the early years, demonstrating strong long-term economic potential.

Hard Chromium plating remains lower in unit cost, however, the MOZART advanced coatings deliver non-financial benefits, such as enhanced wear resistance, extended service life, and reduced environmental and health risks. Between the two coating alternatives, Graphene coatings provide a small cost advantage.

This analysis targets to evaluate the adoption of SiC150 and Graphene coatings in industrial gear manufacturing supporting informed decision-making for manufacturers who need sustainable and high-performance coating solutions.

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.

Per‑ and polyfluoroalkyl substances (PFAS) possess a unique combination of properties—such as exceptional water and oil repellency, high thermal and chemical stability, pronounced oxygen affinity, and effective surfactant behavior—that have enabled their widespread use across industrial applications and consumer products since the 1940s. However, increasing concern over their persistence and potential adverse impacts on human health and the environment has prompted regulatory action. In 2020, the European Union adopted Regulation (EU) 2020/784 to restrict the manufacture and use of persistent organic pollutants, specifically limiting concentrations of PFOA, its salts, and related compounds to a maximum of 1 mg/kg in substances that meet the PFAS definition and are incorporated into consumer products [1].

Given the high persistence of PFAS and significant knowledge gaps regarding the properties, uses, and toxicological profiles of many PFAS currently in use, there is growing consensus that their production and application should be significantly reduced. This drives the need to substitute hazardous chemicals—particularly in consumer-facing applications—with safer, more sustainable alternatives. Developing PFAS‑free coatings that deliver equivalent performance while minimizing environmental impacts across their life cycle remains a major challenge.

The objective of this work is to develop novel bio‑based coatings for the textile and packaging sectors that provide water and oil repellency comparable to PFAS‑based formulations. The new coatings are synthesized from biomass‑derived resources using an environmentally friendly polymerization process. Process parameters and their influence on final material properties were systematically evaluated, enabling the optimization of coatings tailored to textile and packaging applications.

The increasing diffusion of dispersion‑coated fiber‑based packaging has created a growing need for advanced analytical methodologies capable of assessing coating integrity and degradation during recycling. In this work, we introduce a process‑integrated method designed to detect, isolate, and characterize microplastic (MP) fragments generated from thin polymeric films during hydropulping. The approach combines controlled laboratory repulping, aligned with industrial conditions, with a multi‑stage isolation workflow based on sequential filtration and fine‑mesh screening, taking and adapting standard methodologies recognized and used within the sector.
To enhance traceability, selected coating formulations were tagged with rhodamine‑B, enabling semi‑automated MP detection through complementary imaging techniques including fluorescence microscopy, optical microscopy, and Raman spectroscopy. These instruments supported cross‑validated identification of polymeric particles and allowed characterization of fragmentation behavior down to 20 µm. For a representative 8 g/m² thin‑film coating, over 75,000 secondary MPs were recovered from solid residues, with an average equivalent diameter of 75.4 µm and a particle density of 4.7 particles/mm². The study demonstrates how this integrated platform enables the systematic evaluation of thin‑film fragmentation pathways during repulping.
Because this work represents one of the first attempts to apply such an approach to coated fiber substrates, the tests are best understood as preliminary applications of the methodology, illustrating its diagnostic potential rather than providing exhaustive environmental metrics. The framework is inherently scalable and reproducible, offering a powerful foundation for equipment benchmarking, coating‑failure analysis, and process‑control improvement across recycling and coating‑development environments.
Overall, the methodology establishes a new analytical capability for the coating community, supporting Safe and Sustainable by Design (SSbD) strategies aimed at developing next‑generation, high‑performance, and recyclability‑oriented barrier coatings.

Poly- and perfluoroalkyl substances (PFAS) are widely used in industrial applications due to their functional properties; however, concerns related to their persistence and potential adverse health effects are driving regulatory restrictions and the need for safer alternatives. In response, the PROPLANET project aimed to develop PFAS-free coating solutions within the Safe and Sustainable by Design (SSbD) framework, integrating human health hazard assessment throughout the innovation process.

In PROPLANET, hazard assessment was implemented using a tiered approach across the coating development stages. Initially, existing toxicological information on individual coating components was collected through data mining of safety data sheets and regulatory databases, maily ECHA CHEM, to support the selection of safer substances and identify data gaps. Where relevant information was missing, New Approach Methodologies (NAMs) were applied to address data gaps and support early hazard profiling. In particular, in silico models were developed and applied to assess the mutagenicity of PFAS-free alternatives.

Building on this early screening, in vitro NAMs formed the core of the hazard assessment strategy for candidate coating formulations. A structured battery of assays, informed by Adverse Outcome Pathways, was applied to investigate key toxicological endpoints, including cytotoxicity, genotoxicity, inflammatory responses, carcinogenic potential, endocrine activity, and reproductive toxicity. Whenever possible, PFAS-free formulations were tested in parallel with PFAS-based benchmark coatings.

The outcomes of the hazard assessment informed coating development and supported the identification of candidates with lower hazard potential for further advancement. Overall, in vitro results indicated limited adverse effects for most PFAS-free alternatives compared to PFAS-based benchmarks, although some formulation-specific responses were observed and warrant further investigation. By embedding a tiered, NAM-based hazard assessment within the SSbD framework, PROPLANET supports the development of safer PFAS-free coatings and contributes to the advancement and acceptance of NAMs.

Over the past two decades, polymer electrolyte membrane fuel cells (PEMFCs) have made remarkable progress in performance and durability; however, the high cost associated with platinum-based cathodes remains a major barrier to large-scale deployment. In this context, the development of scalable, platinum-efficient oxygen reduction reaction (ORR) electrocatalysts is a critical challenge.

In this work, a scalable electrodeposition approach for the fabrication of nanostructured core–shell (Ni-W)@Pt electrocatalysts with ultra-low platinum loading for PEMFC cathodes is presented. Using pulse electrodeposition, Pt shells were directly deposited onto non-noble Ni-W cores, enabling precise control over nucleation, particle size, surface coverage, and shell morphology while grown directly on the gas diffusion layer. Platinum loadings as low as 0.013 mg cm⁻² were achieved while maintaining homogeneous catalyst distribution.

The catalysts were comprehensively characterized by means of FE-SEM, HR-TEM, and ICP-MS, and their ORR activity was evaluated in acidic media. The optimized (Ni-W)@Pt catalysts exhibited high open-circuit potentials (≥ 0.95–1.0 V vs. RHE) and outstanding mass activities, reaching ~10 A g⁻¹ at 0.9 V, despite the drastically reduced precious metal content. Complementary machine-learned force field simulations provided insight into strain effects arising from the Ni-W core on the Pt shell, supporting the experimentally observed activity performance. Additionally, the influence of Pt loading and mesoporous shell structures on electrode durability is investigated.

The results demonstrate that electrodeposition is an industrially relevant and versatile strategy for producing high-performance, low-Pt PEMFC cathodes, offering a promising pathway toward cost-effective and sustainable fuel cell technologies.

Acknowledgments

Funded by the European Union under the GA number 101058076-NICKEFFECT project. The views and opinions expressed, however, arethose of the author(s) only and do not necessarily reflect those of the European Union or European Health and Digital Executive Agency (HaDEA). Neither the European Union nor HaDEA can be held responsible for them.

Monocrystalline Ni-based superalloys are the current state-of-the-art materials for blades in jet turbine engines . They are coated with thermal barrier coatings (TBCs) including outer layer (top coat) and inner layer (bond coat) for application in the hot section . The former is made of zirconium oxide stabilised with yttrium oxide (YSZ) with a thickness of 100-300 µm, whereas the latter is based on either metallic MCrAlY (M=metal) interlayer or diffusion aluminide layer with a thickness of approx. 80 µm. TiAl alloys, due to a much lower density than Ni-based super alloys (3.7-3.9 vs. 8.0-8.7 g/cm³) stand out as a very interesting alternative for the lower temperature section of the jet engine. What is more, application of a TBC could allow the use of TiAl turbine blades at higher temperatures. But, when TBCs and TiAl alloys are combined, brittle phases are formed at the with the bonding layer (MCrAlY).

The main aim of this work, is to address aforementioned problem with the application of TBCs on the Ti48Al2Cr2Nb (4822) alloy with a bond coat based on polymer-derived ceramic (PDCs) coatings from the SiAlOC system. In [1], SiAlOC coatings were already shown to improve the corrosion resistance of 4822 alloy. TBCs based on YSZ were obtained at several different temperatures (830, 850, 900 and 950°C) using an EB-PVD process. Microstructural studies (SEM and EDS) along with advanced structural studies (Raman confocal imaging ) revealed that the application of the hollow cathode (HC) plasma in the EB-PVD process enabled the successful formation of columnar ceramic coatings at temperatures up to 200°C lower than typical, while still meeting most of the requirements for TBC applications. The coated and bare TiAl specimens were oxidized in lab air for up to 800 h at 750 °C, the current application limit, and 900 °C, the future application aim. Further cross-sectional analysis was done to study the impact of oxidation and the overall adhesion of the coatings.

Acknowledgment: This work was supported by the National Center for Research and Development (NCBR) under the 35th CORNET (COllective Research NETworking) Project, co-funded under contract number CORNET/35/23/PDC-TBC/2024.

The Safe and Sustainable by Design (SSbD) framework supports the development of chemicals and materials by embedding safety and sustainability considerations throughout the innovation process. While the framework is applicable across sectors, its implementation in the plastics value chain remains limited. In this context, the Horizon Europe project ANALYST is developing a tiered and iterative SSbD assessment strategy aligned with technology readiness levels (TRLs), following the Joint Research Centre SSbD methodological guidance.

Across all assessment levels, the ANALYST approach starts with systematic data collection and curation, supported by natural language processing (NLP) tools to extract and organize existing information from diverse sources. Building on this foundation, the safety strategy is structured into three progressive levels addressing human and environmental health. At early innovation stages (TRL 1–3), where data are limited, the assessment relies on New Approach Methodologies (NAMs), with a strong emphasis on the use of in silico tools for hazard identification, and conservative exposure and risk considerations. At intermediate stages (TRL 4–6), in vitro NAMs and more advanced exposure models are integrated, enabling preliminary risk characterization. At later stages (TRL 7–9), the strategy supports comprehensive safety assessment in line with regulatory requirements, covering the full life cycle and value chain of plastic-based materials.

Beyond safety, the ANALYST framework integrates environmental, social, and economic dimensions within the SSbD concept, supported by a digital decision-support tool for multicriteria evaluation. The overall framework is being tested and validated through case studies in the plastics sector, to demonstrate how a tiered, NAM-based safety strategy can inform safer and more sustainable innovation pathways.

The PROPLANET project is a Horizon Europe–funded research and innovation action aiming to develop next-generation, PFAS-free coatings following the Safe-and-Sustainable-by-Design (SSbD) framework. PFAS (per‑ and polyfluoroalkyl substances) are a large group of synthetic chemicals widely used for their water‑, grease‑ and stain‑repellent properties, but they are persistent in the environment, accumulate in living organisms, and are increasingly linked to adverse health and ecological impacts.

PROPLANET project targets three key industrial value chains where high-performance coatings are essential and environmental impact is critical: (i) textiles, (ii) glass, and (iii) food-packaging machinery. Across these sectors, PROPLANET seeks to replace existing coatings that contain PFAS with innovative bio-based and hybrid coating solutions that maintain functional performance while significantly reducing environmental and health risks.

This work emphasises market readiness and exploitation potential of the developed solutions. A comprehensive market assessment was conducted for each value chain, identifying target applications, and end-user needs. Moreover, a structured patent landscape analysis was performed, mapping existing intellectual property, as well as innovation gaps relevant to PFAS-free coating technologies.

To support future commercialisation, tailored business models were developed for key exploitable results, using tools such as the Business Model Canvas. In addition, circularity aspects were assessed to ensure that the proposed coatings contribute to resource efficiency, reduced chemical footprints, and alignment with EU circular economy objectives.

Modern industrial coating applications rely heavily on per- and polyfluoroalkyl substances (PFAS), which are valued for their exceptional functional properties. However, growing evidence of their environmental persistence and potential health risks has prompted regulatory action and an urgent need for safer alternatives. The PROPLANET project addresses this challenge by developing PFAS-free coating solutions using the Safe and Sustainable by Design (SSbD) framework, which embeds human health and environmental safety from the earliest stages of innovation.

Traditional coating development relies on costly trial-and-error experimentation. The PROPLANET Replication Tool transforms this approach by providing a comprehensive digital platform that enables researchers and industry to evaluate new formulations before physical testing. The software is a result of five key inputs: first-principles simulations that examine coating performance at the molecular level; environmental fate models predicting where substances disperse and accumulate in ecosystems; lung exposure assessments evaluating inhalation risks; multi-objective optimization algorithms identifying optimal compound combinations balancing emissions and production requirements; and toxicological risk classification of the compound mixtures, based on the information obtained from the ECHA database.

By centralizing these diverse models into a single, user-friendly interface, the tool allows users to design coating formulations that meet specific performance requirements—such as hydrophobicity or oleophobicity—while ensuring environmental compliance and minimizing health hazards. This data-driven methodology significantly reduces research costs, laboratory waste, and development time, embodying a "First Time Right" philosophy.

Developed as an open-source platform, the PROPLANET Replication Tool democratizes access to advanced simulation capabilities, enabling stakeholders across industries to adopt sustainable practices. This digital innovation represents a critical step toward widespread replacement of PFAS with safer alternatives while maintaining the high-performance standards demanded by modern applications.

Composite nickel coatings obtained via the electrodeposition technique play a major role in various engineering fields ranging from automotive to aerospace. Ongoing research is focusing on enhancing its mechanical properties by embedding in the nickel matrix various strengthening particles in either the nano or the micro scale [1,2]. Nitrogen-doped carbon dots (NCDs) belong to the novel and rapidly advancing subcategory scientific area of carbonaceous nanomaterials, which exhibit improved properties, while they can be produced by green chemistry methods and can be exploited in various fields such as energy, environment or catalysis [3]. Interestingly, only few studies refer to composite nickel-matrix/NCDs and the resulting mechanical properties [4]. In the current study we report the successful incorporation of NCDs, fabricated by hydrothermal treatment and microwave irradiation, in a nickel-matrix coating through a one-step electrodeposition process at the direct current regime. Quantitative stoichiometric analysis of the carbon content in the coatings was achieved by means of an infrared combustion analyzer. In addition, the coatings were studied for their microstructural characteristics and surface morphologies, by means of X-ray diffraction and scanning electron microscopy, respectively. The mechanical properties of the coatings were studied by performing microhardness indentation testing. This study will also permit us to discuss a new additive-free composite nickel coating with enhanced hardness properties to be exploited for potential mechanical applications.