Seals are an essential part of machines with moving parts, from ship propellers and wind turbines to farm equipment and power plants.
They help keep systems running smoothly, often with the help of strong plastic materials and oil-based lubricants.
But there’s a problem—many of these seals contain PFAS, also known as “forever chemicals.”
These substances do not break down in the environment and can pose serious health risks.
On top of that, traditional lubricants made from petroleum can cause massive environmental damage if they leak, with just one liter capable of polluting a million liters of groundwater.
With an upcoming European Union ban on PFAS, industries have been searching for a safer, more sustainable solution.
Researchers from the Fraunhofer Institute for Laser Technology ILT and the Fraunhofer Institute for Mechanics of Materials IWM have developed a promising answer: seals that are completely PFAS-free and work with water-based lubricants instead of petroleum.
This major step forward comes from a project called pureWaterSeal.
The team created a special coating called diamond-like carbon (DLC), designed to work on PFAS-free plastic parts. They also used laser technology to structure the surface of the seal in a precise way.
This method reduces stress in the material and strengthens its durability, making the seals last longer while also reducing friction.
The big win is that these new seals can now operate using water-based lubricants—a major environmental improvement that wasn’t possible before. According to Dr. Christof Koplin from Fraunhofer IWM, this development protects ecosystems by eliminating harmful substances from both the manufacturing process and the final product. The seals are not only safer but also suitable for demanding industrial applications.
To bring this eco-friendly innovation to real-world use quickly, the Fraunhofer team is working closely with companies from different industries.
Prototype seals are already being tested in pumps at geothermal power plants. The next steps include scaling up production and adapting the technology for a wide range of machines and systems.
Plans are also underway to launch a spin-off company to market these seals. The public will get a closer look at this groundbreaking work at Laser World of Photonics 2025 in Munich, where the team will be showcasing the project’s results and future plans.
