University of Toronto Develops PFAS-Free Non-Stick Coating Using Nanoscale Fletching for Sustainable Oil and Water Repellent Surfaces

San Francisco

Researchers at the University of Toronto Engineering have developed a new kind of material using an innovative technique called nanoscale fletching, offering a safer alternative to traditional non-stick chemicals used in consumer products such as cookware and textiles. This novel coating resists both water and oil, functioning effectively as a non-stick surface without relying on conventional long-chain or short-chain PFAS chemicals, which have long been criticized for their environmental persistence and potential health risks.

At the core of the innovation is a very thin layer of polydimethylsiloxane (PDMS), a flexible, transparent, and non-toxic silicone polymer commonly used in contact lenses and medical devices. Although PDMS inherently offers excellent temperature resistance, it lacks the oil-repelling capabilities of fluoropolymer-based coatings such as Teflon based out of Polytetrafluoroethylene (PTFE).

To overcome this limitation, the researchers introduced nanoscale fletching, where the PDMS chains are chemically tethered to a surface, forming dense, brush-like microstructures. The longer and more flexible these bristle-like chains, the more effectively they repel oil. To further enhance oil repellence, each PDMS bristle was terminated with a single carbon atom bonded to three fluorine atoms (–CF?), the shortest and least bioaccumulative PFAS unit currently known.

This strategic use of minimal fluorine content enabled  to achieve Grade 6 oil repellence on the AATCC scale, a performance comparable to many existing commercial PFAS-based coatings. The team successfully tested the coating against a range of low surface-tension oils such as hexadecane, tetradecane, dodecane, and decane, and demonstrated its adhesion on a variety of substrates including nylon, polyester, aluminium, and stainless steel, indicating broad application potential across cookware, food packaging, industrial textiles, and biomedical devices. While the coating is not yet entirely PFAS-free, its drastically lower fluorine content marks a significant step forward in developing sustainable, environmentally friendly, and low-PFAS non-stick materials.

Currently, the research team is exploring further methods to eliminate PFAS content altogether without compromising performance. Their ultimate goal is to create a fully PFAS-free coating solution with oil and water repellency that matches or exceeds that of Teflon, addressing growing regulatory restrictions and consumer demand for non-toxic alternatives. The researchers are actively seeking partnerships with industry stakeholders and manufacturers to scale and commercialize the process. This advancement is considered a giant leap in the field of non-stick coatings, green materials, PFAS alternatives, and sustainable surface engineering, offering promise for a new generation of high-performance, low-impact coating technologies.

At Novatrends Market Intelligence, we continuously monitor such pivotal developments that signal shifts in technology benchmarks and investment outlooks. Our latest research initiatives aim to decode the market potential, regulatory implications, and business opportunities that arise from innovations in solar cooling systems and related passive enhancement technologies.

To facilitate deeper exploration and assist clients in evaluating related market opportunities, readers are encouraged to review the following research areas that directly stem from this technological development:

1. PFAS Market
2. PFAS-free Cookware Market
3. PTFE Market
4. PTFE in Cookware Market