Nickel electrolytic deposition is among the most commonly employed methods for numerous applications. Researchers have extensively examined the influence of various electrolysis parameters, as well as the impact of incorporating various additives or secondary reinforcing agents. Particularly composite Ni-MoS₂ coatings have attracted significant attention because of their enhanced wear resistant properties. In the present study we investigated the wetting properties of electrodeposited coatings fabricated in a Watts-type electrolyte containing MoS₂ nanoparticles at selected concentrations. The electrodeposition was conducted at various current densities by utilizing the standard three-electrode setup. The microstructure of the coatings was studied with x-ray diffractometry (XRD), while the surface morphology through scanning electron microscopy (SEM). The stoichiometric analysis was accomplished by an energy dispersive spectrometer (EDS) coupled on the SEM. Water contact angle measurements were performed by measuring the static water contact angle and the sliding angle at ambient conditions. The results showed that the successfully-prepared nanocomposite coatings exhibited superhydrophobic properties which are enhanced as the current density increases, enabling the utilization of such coatings in self-cleaning and water repellent applications.

Corrugated cardboard is a sustainable alternative for frozen food packaging, but concerns remain regarding barrier performance and substance migration. This study assessed overall migration and the potential transfer of cytotoxic substances from a beeswax–chitosan antimicrobial coating intended for frozen Atlantic cod packaging.

Overall migration was evaluated on coated and uncoated cardboard using TENAX in stainless steel migration cells for 10 days at 40 °C, in accordance with EN 1186. Migration values were 0.233 ± 0.047 mg/dm² for uncoated cardboard and 0.567 ± 0.047 mg/dm² for coated samples, remaining well below the legal limit of 10 mg/dm² established by EU Regulation 10/2011.

To verify compliance with EDQM 2021 requirements for active packaging, agar diffusion tests were performed to assess the transfer of cytotoxic or antimicrobial compounds. Coated and uncoated samples were tested alongside antibiotic controls on agar plates inoculated with Bacillus subtilis and incubated for 72 h. No inhibition zones were observed for coated samples, indicating no compound transfer.

These results demonstrate that the bio-coated corrugated cardboard exhibits controlled migration behaviour and meets current European regulatory requirements, supporting its potential application as sustainable packaging for frozen fish products.

The transition toward a toxic-free and circular economy necessitates a paradigm shift in the development of advanced coatings, Safety and Sustainability must be integrated alongside technical performance from the very beginning. This presentation explores how the Safe and Sustainable by Design (SSbD) framework has been translated into practice through two major European Horizon 2020 projects: ASINA and SUNSHINE.

In the context of the ASINA project, we demonstrated how design strategies were applied to develop high-performance antimicrobial and photocatalytic textile coatings. The core of the approach lies in the definition of a multidimensional "Design Space", where Key Decision Factors (KDFs), such as water-based, room-temperature synthesis and specific deposition parameters (spray coating), were systematically managed. These KDFs were mapped against a "Performance Space" defined by Key Performance Indicators (KPIs), including antimicrobial efficacy (100% bacterial depletion and DeNOx abatement), worker exposure levels, and nanomaterial release during the product’s life cycle. The selection of the most promising SSbD solutions, notably Ag-hydroxyethyl cellulose (AgHEC) and nitrogen-doped TiO₂, was supported by the ASINA Expert System (ES), a multi-objective optimization tool designed to balance safety, functionality, and cost-effectiveness.

In parallel, one of the case studies developed by the SUNSHINE project addressed the challenge of replacing hazardous PTFE-based anti-stick coatings in the bakery industry. A tiered SSbD approach led to the development of multicomponent nanomaterials (MCNMs), specifically core-shell structures like SiC@TiO₂ (Tier 1) and its further optimized alternative SiC@SiO₂ (Tier 2). The study highlights how modifying shell synthesis led to a 50% reduction in environmental impact and a 7% decrease in production costs, while ensuring strict compliance with EU food contact regulations through minimized ion migration.

By synthesizing the outcomes of both projects, this talk will illustrate how the integration of Life Cycle Assessment (LCA), exposure science, and early-stage toxicological screening can drive industrial innovation. The discussion will provide a strategic perspective for designing the next generation of coatings that meet industrial standards without compromising human health or environmental integrity.

Polydopamine (PDA) has emerged as a uniquely versatile, biomimetic polymer with profound implications for environmental, biomedical, and energy applications. However, traditional substrate-dependent deposition methods often obscure its intrinsic supramolecular ordering and limit the fabrication of free-standing architectures. This talk highlights recent breakthroughs in harnessing the air-water interface for the bottom-up synthesis of highly oriented, nanometric PDA thin films. By carefully controlling intermolecular interactions at the gas-liquid boundary, we demonstrate the formation of PDA films with a unique 2D-like layered structure, driven by ordered eumelanin-like protomolecule stacking.

Crucially, this interfacial self-assembly enables extraordinary physical properties that surpass those of conventional PDA coatings. Nanoindentation studies reveal superior mechanical resilience in these films—exhibiting a Young’s modulus of 13 ± 4 GPa and a hardness of 0.21 ± 0.03 GPa—allowing these ultrathin layers to be easily transferred to diverse substrates or utilised as robust, free-standing membranes. Furthermore, we will explore the multi-responsive nature of these polycatecholamine nanomembranes, showcasing their capacity for rapid, reversible mechanical actuation triggered by light irradiation, thermal variations, and atmospheric moisture.

The combination of exceptional mechanical robustness, tunable supramolecular ordering, and stimulus-responsiveness establishes air-water interface-derived PDA thin films as a highly scalable and versatile platform. By connecting fundamental structural analysis with practical utility, this presentation will outline how these free-standing films can be integrated into next-generation technologies, with a focus on advanced electrochemical sensors, energy harvesting, actuators and more.

Magnetic Ni-Mn-Co-In alloys, belonging to the family of magnetic shape memory alloys, exhibit a reversible martensitic transformation that can be triggered by temperature, stress, or magnetic fields, enabling functional strain and field-responsive behawior [1,2]. Translating these properties to coatings and/or additive manufacturing requires powder feedstocks with controlled phase stability and microstructural robustness, because the alloy system is intrinsically brittle and sensitive to processing-induced cracking. In this work, we investigate how minor alloying additions—representing a light element (B) and a heavy element (Mo)—influence the microstructural evolution and transformation behavior of Ni-Mn-Co-In powders designed for thermal spray and powder-bed processing routes. Powders with 0–4 wt.% additions were produced and subjected to tailored thermal treatments to simulate thermal histories relevant to coating deposition and layer-wise consolidation. Scanning electron microscopy and EBSD reveal a matrix–precipitate microstructure, with addition-rich particles dispersed throughout the powder and evolving in volume fraction with composition. DSC shows systematic shifts of martensitic transformation temperatures by ~50–60 K. Phase constitutions and lattice structures are resolved by XRD and TEM, providing guidance for composition–process windows suitable for functional coatings and additively manufactured components.

[1] K. Ulakko et. al., Mater. J. Mater. Engin. Perform. 5 (1996), 405-409.

[2] R. Kainuma, Y. Imano, W. Ito, Y. Sutou, Nature Vol 439 (2006), 957-960.

Plating on Plastics (PoP) is a continuously growing manufacturing technology for the production of several everyday (e.g. home appliances, automotive compartments) and advanced (e.g. aerospace) applications. The traditional process uses toxic Cr⁶⁺ and Pd critical raw material raising environmental, health, and supply concerns. This work presents a process systems engineering framework for the modeling, design and optimization of a novel SSbD PoP technology (EU-Funded FreeMe project) replacing Cr⁶⁺ and Pd with piranha solutions (H₂O₂–H₂SO₄), nickel-salts and NaBH4 for the pretreatment of plastic surfaces before metallization. State of the art and data-driven models were developed for the four proposed novel processing stages (i) etching with piranha, (ii) surface activation with nickel-salts, (iii) surface reduction with NaBH4, and (iv) metal plating.

A contact angle property prediction model was developed as a function of the etching conditions describing the piranha etching mechanism. The clever use of data and models further enables the correlation of contact angle with the hydroxyls surface concentration quantifying etching performance. Next, an activation efficiency model and a surface reduction kinetic model were developed as functions of process conditions. Last but not least, a regression method enhanced with data re-mapping was constructed as an extrapolable model for the prediction of the coating adhesion specification on the plastic substrate with respect to surface characteristics.

The models were constructed as an optimization Decision Support Tool considering economic, environmental, safety and SSbD objectives to assist PoP practitioners optimally tune their pilot/industrial lines for SSbD plating on plastics using the new technology. A BETA version of the DST was developed for stakeholders’ experimentation enabling the user to define their production characteristics and requirements (adhesion, thickness). All process operating variables for PoP of 6 items of 150 cm2 (each) were optimized reaching adhesion (2.5 MPa) and thickness (25 μm) specifications at optimal SSbD criteria.

This presentation argues that progress in coating tribology does not come from reproducing fixed specification values, but from understanding the underlying failure and contact mechanisms. Through several case studies, it shows how conventional specification-driven tests can give misleading or incomplete conclusions when applied outside their original context. Examples include soft polymer coatings on steel, where standard peel and scratch methods fail to detect true adhesion loss; TiN coatings in tribocorrosion, where static corrosion assumptions break down under dynamic sliding conditions; and hard chrome replacement, where matching hardness alone does not reproduce functional performance across different applications. Across these cases, the central lesson is that tribological behaviour is system-dependent, dynamic, and strongly influenced by the interaction between material, environment, and loading conditions. The presentation advocates a mechanism-based pathway for innovation: start from the real failure mechanism, reproduce it at laboratory scale, validate the method, and only then develop standards or specifications. For researchers, engineers, and policy makers alike, the message is clear: sustainable coating development and substitution require functional redesign rather than metric replication.

Chemical vapor deposition (CVD) is a key manufacturing technique widely used in the semiconductor, energy, and advanced materials industries to produce thin films with controlled composition and microstructure. However, the underlying mechanisms governing CVD processes are inherently complex because they involve phenomena occurring across multiple spatial and temporal scales, including gas-phase reactions, transport processes, and surface chemistry. In this study, the interplay between these multiscale effects and the role of operating conditions in determining film growth behavior are systematically investigated. A multiscale computational modeling framework is developed to couple reactor-scale transport phenomena with surface reaction kinetics, enabling a more comprehensive understanding of deposition dynamics. In addition, data-driven analysis methods are employed to identify patterns and correlations between process parameters and resulting film properties. The computational results are validated using experimental measurements, providing insights into how temperature, pressure, and precursor concentrations influence deposition rates and film uniformity. This combined modeling and data-driven approach offers a pathway toward improved prediction, optimization, and control of CVD processes in advanced material fabrication.

Superhydrophobic surfaces have marked increased attention in materials science due to their potential applications in self-cleaning, anti-corrosion, water-repellent, and antimicrobial technologies. Conventional coatings often rely on fluorinated compounds, which raise environmental and health concerns due to bioaccumulation. In this study, a sustainable method was developed to produce silicon-based superhydrophobic coatings via an one-step sol-gel process, applied through a spray-deposition technique using non-toxic solvents. The aim is to fabricate environmentally friendly coatings with high water contact angles on various substrates, offering a safer and effective alternative to fluorinated systems. In this study, a one-step sol-gel synthesis was used to prepare a low-viscosity organosilane solution using tetraethyl orthosilicate (TEOS) and hexadecyltrimethoxysilane (HDTMS) as the primary precursors, with ethanol and water as solvents. The solution was stirred at 60 °C to promote hydrolysis and ensure homogeneous mixing, resulting in a stable sol suitable for coating deposition. The coatings were deposited via a spray-deposition technique that is low cost and easily scalable for industrial use. A wide range of substrates—including paper, metals (Ti6Al4V, Al 1050 H14), plastic, cardboard, fabric, and brick—were coated to demonstrate the versatility of the method. Process parameters such as catalyst type and precursor ratios were optimized to ensure uniform deposition and achieve the highest contact angle with low contact angle hysteresis. Surface morphology was examined using scanning electron microscopy (SEM), while Fourier-transform infrared spectroscopy (FTIR) verified the chemical structure. Water contact angles were measured to confirm the superhydrophobic property of the coated surfaces. For Ti6Al4V, the contact angle reached approximately 164°, with contact angle hysteresis below 2°, as further confirmed by self-cleaning tests on the coated surface. Other substrates exhibited contact angles between 151° and 164°, along with effective self-cleaning performance.

The development of sustainable corrosion-protective coatings from renewable feedstocks has attracted growing interest as an alternative to conventional petroleum-based systems. In our earlier work, we investigated bio-based coating platforms derived from cyclic carbonated vegetable oils, particularly cyclic carbonated soybean oil (CSBO), for the preparation of non-isocyanate polyurethane (NIPU) and hybrid networks with promising corrosion resistance on aluminium substrates. Building on these findings, the present study explores cardanol-based coatings as a complementary bio-derived approach for advanced surface protection.

Cardanol, obtained from cashew nut shell liquid, possesses a unique molecular structure comprising an aromatic ring and a long hydrophobic aliphatic side chain, making it an attractive precursor for protective coating applications. These structural features are expected to enhance coating hydrophobicity, barrier performance, and resistance to electrolyte ingress, all of which are critical for long-term corrosion mitigation. Drawing from our previous understanding of bio-based network formation, curing behavior, and coating–substrate interactions, this work examines how cardanol-based chemistry can be leveraged to achieve durable and environmentally responsible corrosion protection.

The study correlates the present cardanol system with our prior investigations on CSBO-based NIPU and hybrid coatings, with emphasis on coating formation, structural evolution, and electrochemical performance. The coatings are evaluated using FTIR, thermal analysis, surface wettability, morphology, electrochemical impedance spectroscopy, and polarization measurements to establish structure–property–performance relationships. Overall, this work highlights cardanol as a promising renewable building block for corrosion-resistant coatings and demonstrates how insights from earlier vegetable-oil-based systems can guide the design of next-generation sustainable protective materials for metallic substrates.