The growing problem of invasive mussel species in the Great Lakes has prompted researchers to create innovative solutions aimed at preventing their spread to inland lakes and reservoirs. These mussels attach to various surfaces, both in the upper (epilimnion) and deeper (hypolimnion) layers of lakes. During the winter months, mussels will die off, leaving the large structures constructed of their shells on the lakebed. Their colonies recede into the deeper waters where water temperature is warmer than the icy conditions on the surface. In the spring and summer, the mussels return shoreward, recoating the left-behind shell structures and adding layers of shell material to the submerged landscape. Juvenile mussels are released from fish hosts and can migrate or float to nearly any structure or vehicle, with bilge water from ships often transporting them to new locations. Once attached, mussels begin their reproductive cycle, and this adherence is key to their spread. If prevented from attaching, they are forced to relocate, increasing competition for space and resources.

To combat fouling, researchers have developed a clear, tri-cure hybrid silsesquioxane coating that is inexpensive, easy to apply, and safe for aquatic environments. When applied to glass or fiberglass, materials they readily attach to, this coating prevents the bonding of mussel proteins to surfaces, making them resistant to fouling. By coating boat hulls, boat owners can reduce mussel attachment, slowing the spread of invasives, saving on costly maintenance, reducing drag, and contributing to the protection of other aquatic ecosystems.

Introduction

Marine biofouling, which is the undesirable accumulation of microorganisms, plants, and animals on submerged surfaces, poses significant operational and environmental challenges to maritime industries and aquatic infrastructure.^1-3ĢżThe consequences of biofouling are far-reaching. It causes increased hydrodynamic drag on vessel hulls which reduces fuel efficiency and speed, while simultaneously contributing to higher greenhouse gas emissions.^4-7ĢżIn addition, biofouling accelerates the corrosion of submerged metal and concrete surfaces, clogs pipelines in coastal and nuclear facilities, and disrupts water flow and nutrient exchange in aquaculture systems.^8,9

One of the most practical and effective strategies for mitigating biofouling is the use of protective surface coatings or coating additives. These are broadly classified into biocidal and nonbiocidal types. Biocidal coatings rely on the controlled release of toxic agents from a polymer matrix to prevent organism settlement and are considered antifouling coatings.¹⁰ĢżThe efficacy of such coatings is governed by the biocideā€™s release rate and its environmental compatibility that should ideally combine strong antifouling activity with low toxicity and moderate fresh and sea water solubility. Unfortunately, only a limited number of biocides meet these stringent requirements for safe and sustained marine use.¹¹

Nonbiocidal coatings primarily include fouling-resistant and fouling-release coatings (FRCs). Fouling-resistant coatings are typically based on hydrophilic polymers such as poly(ethylene glycol) (PEG) and zwitterionic materials, which prevent initial organism adhesion.¹²ĢżHowever, their tendency to swell in saline environments leads to poor mechanical performance. In contrast, FRCs utilize hydrophobic, low-surface-energy materials that allow weakly adhered organisms to be easily removed under mild shear forces. Polysiloxanes are commonly used as FRCs and offer excellent thermal and photochemical stability, though their long-term performance is limited by hydrolytic degradation. To overcome these limitations, hybrid organo-silicon coating systems have been developed. These systems integrate organic and inorganic elements to combine durability, antifouling characteristics, and environmental resilience.^13,14ĢżFor instance, R-alkoxysilanes, particularly methoxy and ethoxy variants, have long been employed to consolidate porous substrates like stone by forming crosslinked siloxane networks with the ratio [RSiO_3/2], or silsesquioxanes that also contain organic bridges. When incorporated into coatings, these networks offer benefits such as low thermal conductivity, oxidative resistance, and mechanical integrity.

Among silicon-oxygen-based coating systems derived from alkoxysilanes, tetraethoxysilane (TEOS) is a widely used precursor.^15,16ĢżHowever, its slow curing rate often necessitates acidic or basic catalysts and long reaction times. As an alternative, photocuring methods that utilize photoinitiators to trigger rapid organic polymerization under light have gained popularity for enabling fast curing without complex handling or component separation. Moreover, using R-functional trialkoxysilanes with epoxy, amine, thiol, or fluorocarbon side groups allows tailoring of surface adhesion, hydrophobicity, and internal stress relief within the final silsesquioxane-based coating.¹⁷

Bioinspired approaches have further guided the design of antifouling surfaces. Many plants and insects feature microstructured, waxy coatings that combine hydrophobicity with self-cleaning properties. Mimicking these strategies, coatings with nanoscale surface roughness and low-surface-energy materials (e.g., fluoropolymers) have been developed to enhance water repellency and reduce biological adhesion.

The construction industry is experiencing a paradigm shift from focusing solely on sustainability to embracing comprehensive resilient design, driven by increasingly severe weather events and rising financial risk. While sustainable design emphasizes minimizing environmental impact and resource conservation, resilienceā€”the capacity to adapt and maintain functionality after a disturbanceā€”demands a systems-based approach that addresses future-looking hazards like high winds, hail, fire, and flooding. This article argues that true durability requires building materials, including advanced coatings, to work collaboratively as integrated systems to resist extreme loads that exceed minimum building code requirements. It explores current design resources like LEED v5 and FM Global standards, and provides specific examples of how materials are engineered to resist hazards. These examples include multilayer roofing systems designed for very severe hail, and innovative coatings and membranes used in water-retention assemblies to manage urban storm runoff. Ultimately, resiliency is redefining what it means to create durable, lasting buildings, positioning systems-level thinkingā€”rather than isolated product propertiesā€”as the foundation for a future-proof built environment.

Introduction

Resilient design has become a catchphrase within the construction and architecture communities. Over the last two decades, forward-thinking designers and building owners have focused not just on the now, but on the future, when determining their designs. This challenge started with a focus on sustainability. The U.S. Green Building Council (USGBC) defines sustainable design as “creating places that are environmentally responsible, healthful, just, equitable, and profitable.”¹ĢżSustainable solutions often refer to minimizing the burden on the natural environment, recycling, and conserving energy and other natural resources. These goals have created a multitude of industry buzzwords, including durability, recycled content, energy efficiency, and carbon neutral. However, sustainability is not the same as resiliency.

Resilience is defined by the Resilient Design Institute as “the capacity to adapt to changing conditions and to maintain or regain functionality in the face of stress or disturbance. Resilient design solutions often consider durability as well as the ability to keep a building functional after a weather event.”²ĢżSolutions such as having a generator to maintain power are very resilient, though not necessarily sustainable (Figure 1). To be truly resilient, designers and building product manufacturers must look at more than product properties such as Volatile Organic Compounds (VOC) and embodied carbon, often the go-to for sustainable design, and more at materials working together as systems. There is no one property that ensures resilience. Designers and manufacturers need to collaborate to create complete systems of materials that work together to achieve a successful outcome. The ultimate goal is for designed solutions to meet both sustainability and resiliency targets, such as slowing the release of storm water to prevent overloaded sewers while also using some of the captured rainwater for irrigation.

One example of resilient design is the Sand Palace, which was one of the only structures left standing in its area after Hurricane Michael in 2018. Built specifically to withstand severe storms, the house utilized advanced materials like insulated concrete forms (ICFs) and was designed to resist winds of up to 250 mph, significantly exceeding state building codes at the time. The homeowner explained that they deliberately went “above and beyond code” when making material and design decisions by consistently asking, “What would survive the big one?” It is estimated that the house cost 15-20% more as a result of these decisions. Although they did have to replace utilities and experienced the loss of the first floor along with one of the air handlers, the overall damage was minimal compared to the surrounding properties.

Resiliency has become an important design strategy for many reasons, but the primary driver is money. It is expensive to rebuild after severe weather events, and insurance companies are noticing. In some parts of the United States, it is becoming more expensive and more difficult to get insurance, particularly in coastal regions and areas prone to wildfire. For example, a 2024 report from the Senate Budget Committee shows that the nonrenewal rate in Florida increased 280% between 2018 and 2023.³ĢżAdditionally, FM Global, one of the largest insurers of commercial properties, continues to expand the areas where their buildings must meet very severe hail requirements.

On the residential side, prospective homebuyers are paying attention to the potential weather impacts on properties. In 2024, Zillow started posting hazard ratings for climate-related impacts such as flood, wildfire, wind, heat, and air quality on property listings.⁴ĢżAs with other trends within the construction industry, significant attention is paid when there are clear drivers to profits and losses. This article introduces published resources and references being used by designers to design for resilience. It then looks closely at specific examples in which coatings and other building materials work together as systems to withstand increased building loads.

Epoxy resins have been used for decades in applications demanding excellent adhesion and corrosion resistance, but historically, they have not been suitable for coatings where ultraviolet (UV) resistance is needed. A direct-to-metal (DTM) coating, comprised of a novel modified cycloaliphatic epoxy resin combined with a lower yellowing amine curing agent, was designed to deliver superior performance in corrosion resistance and adhesion. Additionally, this epoxy resin system offers improved gloss retention and color stability compared to standard epoxy coatings.

Both the resin and curing agent are optimized to minimize dry time while maximizing hardness development. The relationship between epoxy-amine stoichiometry and coating performance was evaluated to further improve the system. Comparative testing with a commercially available epoxy-polyamide DTM coating showed that the novel epoxy system performed well against the competitive material while significantly improving the UV resistance, as determined by gloss and color retention.

Introduction

Brief History of Epoxy Coatings Relevant to DTM Applications

For decades, it has been widely known and accepted that coatings based on aromatic epoxy resins (typically based on bisphenol A) and cured with amines perform poorly in exterior or UV-exposed applications.¹ The literature on potential mechanisms causing this poor performance is extensive, but essentially the main arguments for consideration here involve photodegradation and microstructure rearrangement that lead either to discoloration through chromophore generation (understood as yellowing), loss of gloss, or both.^2,3 Were it not for these mechanisms, epoxy coatings would likely have little to no need of further development for industrial DTM applications since the remainder of properties achievable with typical epoxy coatings is generally desirable, especially resistance to corrosion and chemicals. Often, a formulatorā€™s first choice for improving the known deficiencies of standard epoxy resin would be to mitigate UV sensitivity with additives such as hindered amine light stabilizers (HALS) and ultravioletĢżabsorbers (UVAs), and in many cases improved results are achieved, but this approach is more of an incremental improvement than stepwise.⁴

With protective industrial coatings, application time and labor are particularly expensive, so the more layers of coating that are needed to satisfy the technical requirements, the higher the project costs will be. It is apparent that a single-layer DTM application that can meet all customer needs offers great value for formulators and applicators. Current product offerings tend to be either DTM epoxy systems with excellent corrosion and chemical resistance, but higher yellowing, chalking, and gloss loss that are not suitable for exterior or UV-exposed applications, or DTM options based on urethane or acrylic technology that mitigate the UV resistance issues of epoxy while also giving up other desirable characteristics, rendering them unfit for many protective DTM applications. To satisfy an unmet market need, new coatings technology is needed in the form of a lower yellowing epoxy resin for industrial DTM applications that can perform in both UV and corrosion resistance.

Baseline Performance of Common Epoxy Resins

Before developing a novel epoxy resin for industrial DTM applications, it was deemed necessary to evaluate the relative coating performance of common epoxy resins to define the deficiencies. To simplify, future references to “Standard Epoxy” can be understood to denote a typical resin blend (epoxy equivalent weight āˆ¼ 188 g/mol) consisting of diglycidyl ether of bisphenol A (DGEBPA), diglycidyl ether of bisphenol F (DGEBPF), and an epoxy-functional reactive diluent, and any reference to “Cycloaliphatic Epoxy” represents the diglycidyl ether of hydrogenated bisphenol A. For curing agents, “Standard CA” is a typical isophorone diamine (IPDA) adduct with DGEBPA and other formulated components, typical of many products in the epoxy curing agent market, while “LY CA” represents a modified cycloaliphatic amine composition, for improved lower yellowing performance.⁵

Unless otherwise noted, all coatings tested were applied via drawdown (DFT of 3-4 mils) and cured at 25 Ā°C, 50% relative humidity onto the respective substrates needed for the various tests performed. For comparing UV resistance of Standard Epoxy and Cycloaliphatic Epoxy with both Standard CA and LY CA, a cyclic QUV-A test was performed according to ASTM G154, Cycle 2 (8 h at 60 Ā°C UV exposure, 4 h condensation at 50 Ā°C) on coatings applied to Q-PANEL A-36 substrates. Figure 1 shows that there is a significant decrease in observed color change when using Cycloaliphatic Epoxy versus Standard Epoxy, as expected.

FIGURE 1 Ī”E vs time in cyclic QUV-A for clearcoats of various epoxy resins and curing agents.

While the shift in yellowing resistance from Standard Epoxy to Cycloaliphatic Epoxy is greater than that from Standard CA to LY CA, to achieve long-term UV resistance in a lower yellowing DTM system, both resin and curing agent should be capable of superior yellowing resistance. Although coatings made with Cycloaliphatic Epoxy display good UV resistance, this comes with a significant decrease in cure speed (observed by users as an increase in dry times). To establish the performance gap of Cycloaliphatic Epoxy cured with LY CA versus Standard Epoxy cured with LY CA, circular drying times were determined (following ASTM D5895) on coatings applied to Form 1A Penopac Charts. In addition to the earlier systems, a modified cycloaliphatic epoxy resin designed for lower yellowing, faster cure concrete coatings (now referred to as Accelerated Cycloaliphatic) was included to represent a lower yellowing control with acceptable drying time. All systems were formulated according to the recipe in Table 1 with resin, curing agent, and pigment loadings adjusted appropriately to yield a High Gloss White Enamel with an epoxy:amine stoichiometry of 1:1. Circular dry times are listed in Table 2.

Waterborne coatings significantly reduce VOC emissions and improve air quality compared to traditional solvent-based systems. They offer strong performance, durability, and versatility across architectural, industrial, and automotive applications. CoatingsTech talks with Dr. James W. Rawlins from the University of Southern Mississippi about the future of waterborne coatings both in the industry and at the university level.

Q: What are the most recent noteworthy advancements in waterborne performance?

A: In the last few years, exterior-durable latex platforms enabled by reactive polymer-bound surfactants have been a consequential step forward. By copolymerizing reactive/polymerizable surfactants into the latex backbone, concerns associated with surfactant migration, water uptake, and sensitivity have been mitigated, which have historically been issues with waterborne films. Additionally, modern waterborne polyurethanes and polyurethane/acrylic hybrids are now becoming available from experimental/laboratory and commercial materials.

Q: Where is the next big leap likely to come from?

A: There is a lot of research activity happening right now. Innovations in dynamic covalent networks show near-urethane mechanical energy absorption methods, resulting in circularity, repairability, and potential recyclability, in addition to higher crosslink network control and tunable mechanical deformation processes. There is also significant work being done on designed stratification and hybrid lattices in PU-acrylic and silicone-acrylic systems.

In the short term, there is strong progress coming from advancements in additives. Reactive and anchored additives are particularly promising. Another strong area in additives is platelet barriers and rare-earth/organophosphate inhibitors, but the fastest acceleration is happening in testing and digital technology. New methods are being developed for early detection and quantification of failure before they become visible macroscopically.

Q: How can formulators meet sustainability targets without sacrificing durability?

A: In several ways. Water uptake could be reduced at the source by using reactive surfactants and polymer-bound stabilizers, and free, mobile surfactants could be avoided wherever possible. Crosslink density should be driven down with low volatile organic compound chemistry: driven mainly through carbodiimide, blocked-isocyanate, or self-crosslinking mechanisms in acrylic/polyurethane dispersion hybrids. Barriers could be built but understanding and quantifying water, electrolyte, and oxygen barrier differences for common chemistries is needed.

Q: How do universityā€“industry collaborations accelerate innovation?

A: Learning is best achieved through immersion. The combination of total immersion and timeline-driven projects, which is something industry needs, with solid fundamentals such as scientific goals and objectives in an integrated team, drive real depth and real-knowledge gains through necessity. These combined teams are driven by student enthusiasm, industry support, and passionate scientist and engineering personnel with experience. Flagship consortia move students from working with the theoretical to the practical, with fundamental concepts moving into products, as well trained and developed students drive new paradigms.

Q: What excites you most about the future of waterborne coatings?

A: There are many. One is one-pass which are self-organizing films, stratifying hybrids, that can deliver stain resistance and direct-to-metal (DTM) corrosion without extra layers. Another important contribution is novel material compositions that are sustainable and circular, and dynamic networks enabling repairable, recyclable waterborne films with high chemical resistance. Lastly, data-driven developments such as AI data gathering for machine learning that is linked to accelerated tests in a context of real test results are beginning to remove blind spots for unquantified or poorly connected concepts and this improves upon our scientific rationale moving forward and shrinks lab-to-field translation cost and time.

James W. Rawlins is a professor of Polymer Science and Engineering at the University of Southern Mississippi, where he has directed an 11-member research group focused on Surface Coatings and Circular Materials since 2004. Rawlins, chairman of The Waterborne Symposium, has published 61 peer-reviewed articles and holds 17 U.S. and European patents. Earlier, he served as technical director at Highland International and held R&D and European technical marketing roles at Bayer (now Covestro) in Pittsburgh and Leverkusen.

By Brian Vest, Lichang Zhou, Linda Adamson, and Celine Burel, Syensqo

Perfluoro-and polyfluorinated-alkyl substances (PFAS) have been widely used for a variety of applications, including water-resistant fabrics, nonstick cookware, stain-resistant carpets, firefighting foams, food packaging, and some personal care products. Their unique properties of resisting heat, oil, grease, and water make them highly versatile across various sectors. One type of these chemicals, fluorocarbon surfactants (FCS), has been used specifically in waterborne coatings for improving early “hot block” resistance. However, risk management and upcoming regulations are driving formulators to eliminate the use of these chemicals from their formulations. This has led to a balancing act for formulators as they try to move to more sustainable additives without sacrificing performance.

This study will cover the efforts made in our group for the use of novel phosphate ester wetting agents which deliver improved early hot block resistance without the adverse environmental concerns of fluorocarbon chemistry. These novel alkyl phenol ethoxylate (APE)-free and very low volatile organic compound (VOC) specialty additives deliver improved colloidal stability, which helps provide a combination of wetting, dispersing, and compatibility properties to the finished water-based coating. Data will highlight overall paint performance and touch upon structure/property relationships that lead to improved anti-blocking performance.

Introduction

Manufacturers of waterborne coatings are increasingly facing stringent regulatory requirements to transition towards environmentally sustainable formulations. These formulations must not only exhibit low volatile organic compound (VOC) levels but also eliminate hazardous substances such as alkyl phenol ethoxylates (APEs) and fluorocarbon surfactants (FCS). This regulatory landscape presents a formidable challenge for formulators who are tasked with integrating eco-friendly additives while maintaining the integrity and performance of the coatings.

FCS pose a particular challenge for formulators due to their distinctive molecular structure and the comprehensive balance of properties they impart to formulations. A critical performance attribute provided by FCS is early-stageā€”specifically, 1-day dryā€”hot block resistance. This property is essential in waterborne semi-gloss to gloss formulations designed for low-VOC applications. For decades, FCS have been instrumental in achieving this performance characteristic without adversely impacting other application properties. However, FCS belong to a broader category of chemicals known as perfluoroalkyl or polyfluoroalkyl substances (PFAS), which are classified as substances of very high concern (SVHC). PFAS are of significant health concern due to their persistent nature, as they do not readily degrade and can accumulate in the environment and in the human body over time, earning them the moniker “forever chemicals.”¹ Consequently, there is mounting regulatory pressure globally to identify safe and environmentally benign alternatives to fluorosurfactants across various industries.

In response to the demands within architectural coatings, an extensive study of alternative technologies was undertaken, with a concentrated emphasis on waterbased architectural coatings. This rigorous investigation identified that modifications to a specific phosphate ester chemistry could provide an effective solution, yielding superior early-stage hot block resistance while maintaining a comprehensive balance of application properties. This research culminated in the development of an innovative anti-blocking additive tailored for waterborne coatings.

Background

Block resistance is the capability of a paint when applied to two surfaces to not stick upon contact when pressure is applied under various temperature and humidity conditions. For example, good block resistance helps keep a door from sticking to the jamb or a window from sticking to its frame. When the two painted surfaces are pressed together, chain diffusion and entanglement occur from the mobile polymer chain ends, resulting in poor block resistance. Several factors can influence the blocking resistance of a formulation, such as the polymer T_g, the formulation space, and the type of surface-active additives being used. Figure 1 is a cartoon schematic demonstrating good and poor block resistance.

FIGURE 1 Cartoon schematic of block resistance.

FCS are commonly used to improve blocking resistance in waterborne formulations by providing a “protective layer” at the surface, thereby preventing the polymer-to-polymer entanglement (Figure 1). However, due to the environmental challenges and regulations of fluorocarbon chemistry, formulators need a new additive solution to improve block resistance. The scope of this project was to identify an additive that could be easily used by the formulator, either as a post-add to an emulsion or added directly into the formulation, which could match the block resistance performance of fluorosurfactant chemistry without the environmental concerns.

CHARLES HEGEDUS

Industry Consultant

Could you please share your current role, what it entails, and what excites you most about it? Currently, I work as a coatings industry consultant, following 43 years working as a coatings scientist for an end user and then a raw materials supplier. I mainly work with coating manufacturers to solve formulation problems and coating failures. Iā€™m excited to use my career experiences to solve a wide range of problems and to help others in the coatings industry.

What brought you to the coatings industry? Was it part of the plan, or did you discover coatings along the way? Working in the coatings industry was not part of the plan when I majored in Chemical Engineering in college. In my second year of college, I obtained a co-op position in the coatings laboratory of a Materials Division at a U.S. Naval R&D facility. I helped develop new coatings and corrosion preventive materials for aircraft and other equipment. I loved the work and they offered me a scholarship and a full-time position when I graduated.

How important has mentorship or a piece of advice from someone been in your careerā€”and have you had the chance to mentor others in return? Mentorship played a critical role in my professional development and throughout my career.Ģż I worked with tremendously talented, experienced people who taught me a lot about chemistry, materials, working in a lab, and working in a team. In addition, I was fortunate enough to join and participate in coatings societies and interacted with many of the historic technical icons in the coatings industryā€”many of whom I built career-long relationships that continue to this day. They taught me a tremendous amount. If I didnā€™t know the answer to something, I knew experts who would give me the answer or direct me to it. This served me well over my entire career. I have paid this forward by mentoring many that Iā€™ve worked with, from I also have learned. These relationships have provided me a very fortunate and rewarding career.

How, if at all, did your educational background shape your path into coatings?Ģż When I started my co-op position with the Navy, I was majoring in Chemical Engineering, which gave me a great technical foundation in many areas, especially technical problem solving. I realized I needed to learn more about materials, so I extended my formal education to earn M.S. and Ph.D. degrees in Materials Science.Ģż This combination of Chemical Engineering and Materials Science formal training fit perfectly with my career progression.

Whatā€™s one project or innovation youā€™ve worked on that youā€™re especially proud of? In the past, typical aircraft coatings and many industrial coatings systems consisted of an epoxy primer and a polyurethane topcoat, each providing specific essential functions. By inspecting aircraft and having discussions with hands-on maintenance crews, I realized a lot of time, money, materials, and hazardous waste could be saved by developing one coating to do the functions of twoā€”a self-priming topcoat. Our team developed such a coating. In fact, we developed an entire family of coatings from many polymer systems. I believe we have 15-20 patents on this technology, which is used in some applications today.

Also, many years later, when consulting, I was tasked with developing a resin/composite system to be used in repairing bone fractures in place of traditional metal rods, which seemed drastically different than coatings technology. Initially, I had no idea how to do this; but my materials and coatings technology experiences led me to develop a biodegradable polyurethane/glass fiber composite that could be used for bone repair reinforcement and then would biodegrade in the body once it was no longer needed, thus avoiding a second surgery. This technology also has been awarded several patents. This development clearly illustrates the wide scope of coatings technology and how it can be utilized in other scientific areas.

How do you stay current with advancements in coatings technology? Reading as much literature as I can, listening to lectures, and talking with my industry peers.

Are there any misconceptions about your role or industry that youā€™d like to correct? Once I was labeled as ā€œjust a paint guy.ā€ I think Iā€™ve demonstrated that coatings technologyā€”and my knowledge and experienceā€”spans well beyond coatings technology, which is itself extremely complicated. Consider thisā€¦ almost everything we see is painted in some fashionā€”vehicles, airplanes, road markings, clothing fibers, even playing cardsā€”and all these coatings serve a critical function that supports the success of the end product. The coatings industry is large, itā€™s important, and itā€™s scientifically complicated.

Have you faced any significant professional challenges, and if so, how did you overcome them? The major professional challenge Iā€™ve faced, other than solving difficult technical problems, has been simply growing my knowledge and experience to enable me to solve more problems.

What trends or developments do you think are shaping the future of coatings?Ģż Definitely environmental concerns. Many of these concerns are driven by regulations, which are forcing advanced technical developments to minimize environmental and health issues, while maintaining performance. This is a very difficult challenge.

Are there particular industry innovations or shifts youā€™re excited about? All of them!

What skills or traits do you think are essential for success in this industry? A desire to learn and grow from many sources. The ability to address complex issues.Ģż Think about itā€¦ many coating formulations contain 15-20 ingredients.Ģż From a thermodynamic perspective, how likely is it to have that many ingredients be compatible and stable? This is only a part of the complexity of coating formulation, manufacturing, application, and in-service performance. Successful coatings technologists need to be prepared to learn and then apply this knowledge to the complicated issues within coatings technology.

What advice would you give someone just starting out in the industry or considering a career in coatings? Learn, read, interact, do.Ģż From my experience, the more you learn, the more you can do. And the more you do, the more you learn. Itā€™s a very real, self-fulfilling progression that leads to success.

Whatā€™s something people outside the industry might not understand or be surprised to learn about working in coatings? ĢżItā€™s very complicated and also very important to society.

Do you have any professional goals that youā€™re still eager to accomplish?Ģż Continue to contribute to the growth and success of coatings technology and the coatings community.

How does company culture impact your work and ability to perform successfully? A strong team culture and performance, even with a collection of mediocre team members, is much more productive and successful than a dysfunctional group of highly intelligent individuals. The collective intelligence of a strong interacting group is always smarter and more successful than a single brilliant individual. And an important contributing factor is diversity of knowledge and experience. The technician applying the paint makes just as much of a contribution to the paintā€™s success as the chemist who synthesized the ingredients and the formulator who developed the paint.

What keeps you motivated and eager to come to work each day? ĢżAll of the above.

Charles Hegedus, Ph.D., is a coatings industry consultant and serves as technical editor for both CoatingsTech and the Journal of Coatings Technology and Research.

ĢżReturn to Voices in Coatings: One Industry, Numerous Paths

AMY FREDERICK

R&D Scientist, CARLISLE WEATHERPROOFING TECHNOLOGIES

Could you please share your current role, what it entails, and what excites you most about it?

I am a R&D scientist and I develop and help launch innovative energy-saving coating solutions for the roof restoration industry. Buildings make up over 30% of all energy usage globally, and our mission at Carlisle is to be the leading supplier of innovative building envelope products and solutions for more energy-efficient buildings. I feel my work aligns with the heart of our companyā€™s mission, while also contributing to the companyā€™s sustainability strategy to manufacture more energy-efficient products. While I have experience in other coatings, I am super passionate about roof coatings because I get to use my paint experience as well as my microbiology background. So, I was extremely excited when Carlisle offered me the opportunity to be a part of their team.

What brought you to the coatings industry? Was it part of the plan, or did you discover coatings along the way?

My entry into the coatings industry was unorthodox. After graduating from college, I accepted a medical laboratory scientist role with the Cleveland Clinic in their Pathology Department. However, I realized that I wanted a role in which I could use my creativity. While looking for a job, a recruiter from a staffing agency called and said I would be a great fit for a temp position with Sherwin-Williams. I was obviously a bit confused how my medical lab experience would translate to good paint experience, but I thought, why not, Iā€™ll give working in a paint lab a shot. I liked it enough to stay.

How important has mentorship or a piece of advice from someone been in your careerā€”and have you had the chance to mentor others in return?

I have only been in the coatings industry for about six years, so often, Iā€™m the one being mentored. But there was one piece of advice I received early in my career that has really stuck with me. Iā€™m interested in innovation, and I would develop all these occasionally outlandish, ideas. My marketing manager at the time told me, ā€œIt doesnā€™t matter if youā€™re able to come up with a groundbreaking concept if I canā€™t sell it.ā€ That insight was a game changer for how I approached idea generation. After that, a lot more of my ideas were making it past the initial screening stage.

How, if at all, did your educational background shape your path into coatings?

My education really did not shape my path into coatings, but that has been a benefit. It has enabled me to not overthink things and Iā€™ve found myself more willing to experimentā€”trying things I might not have if Iā€™d had more knowledge.

What is one project or innovation you have worked on that you are especially proud of?

I once pitched an idea that combined my previous experiences with existing technology. My employer at the time gave me 30 days to complete a proof-of-concept to investigate my idea, which sought to detect and prevent product failures. It was a remarkably interesting 30 days.ĢżOn day three, I threw out the project plan I had worked on for six months!ĢżBy day 26, my method was able to produce a different response, capable of replication, based on the presence or absence of certain markers.ĢżIā€™m sure the whole building could hear me celebrate!ĢżI was a lab technician when I pitched this, and it meant a lot to have had the opportunity to run with it and succeed.

How do you stay current with advancements in coatings technology?

I read and research a lot, even outside of work. I just have a voracious sense of curiosity that encourages me to learn and experience as much as I can but also to question the current status quo and think of ways to make something even better.Ģż This is not only limited to coatings articles. I read anything that piques my curiosityā€”and this includes anything from crime, geology, archeology, physics, biology, polymer science, etc.

Are there any misconceptions about your role or the industry that you would like to correct?

That you need to be a chemist or have a chemistry background to formulate paint.Ģż Having a background most certainly helps but, in my experience, soft skills, such as curiosity and willingness to learn and collaborate, are more important. I learned everything I know about paint from a combination of mentorship, internal company training, trial and error, and experimentation. One great thingĢż about the paint industry is that even if you have a nontraditional background, if you are curious and motivated to learn, you can be successful in this industry.

Have you ever taken a detour or changed directions in your career? What did that pivot teach you?

Yes, I have been in a role where, in hindsight, I should have left much sooner than I did. It was a difficult and stressful situation that over time was eroding my sense of self and confidence. I tried white-knuckling through everything because I was under the misconception that if I left, I would be leaving all my successes and ideas behind, and I would never have another opportunity to work in coatings again. While leaving was the hardest thing I had to do, it was the best pivot I could have made. I learned that no job is worth losing oneā€™s self-confidence and self-respect over.

Have you faced any significant professional challenges, and if so, how did you overcome them?

Definitely. Iā€™ve really had to take ownership of my career, and advocate for myself. Iā€™ve been in situations where I was pressured to let others take credit for my work, where I have been told to stop ideating, where I was told that my ideas are going to fail before any of the work started. I have overcome these situations by seeking out people within the organization that I can run an unusual concept by and who will respond by being curious rather than dismissive. I have addressed challenges by advocating for myself when it comes to work, and even leaving a role when that work was not recognized. Most importantly, Iā€™ve developed confidence in myself so I am able to navigate and weather these situations.

How has the coatings industry changed since you entered it?

There is a divide between the formulators, who work on creating new formulations, and lab technicians, who test those formulations to simulate real world conditionsā€”one that Iā€™ve noticed has been increasing. Iā€™ve been in both roles, and I strongly believe that experience as a lab technician has only made me a better formulator. Some of the most talented formulators I have been able to work with still spend time in the lab to keep their wet skills sharp. Even if there are times when I donā€™t directly make batches or perform testing, I always encourage those who help me to give me their observations, feedback, or ideas. I am always impressed with their insight and knowledge.

What trends or developments do you think are shaping the future of coatings?

I think there is an overall trend in the coatings industry to push toward more innovative solutions that avoid the use of harsh or less environmentally friendly chemicals. There is huge push in the roof coating industry to develop coatings that are resistant to microbial growth and to improve the ability of coatings to stay clean. Currently the industry relies on biocides to restrict microbial growth but with regulations limiting the type or amount of biocide that can be used, roof coatings are soiling faster, which reduces their longer-term energy-saving properties. So, finding alternative chemical-free methods to prevent mildew and mold growth is something I have done a lot of research on and get excited about.

Are there particular industry innovations or shifts youā€™re excited about?

Iā€™m super excited about adaptive/responsive as well as sustainable coatings.

What skills or traits do you think are essential for success in this industry?

Curiosity. I donā€™t think I would have done well in this industry if I didnā€™t have a strong sense of curiosity. My curiosity has enabled me to learn, to question and, when I didnā€™t have the knowledge, to reach out to others in the company who did and learn from them.

What advice would you give someone just starting out in the industry or considering a career in coatings?

Never let your lack of knowledge, experience, and feedback hold you back from pitching ideas or having ideas rejected stop you from submitting more. Every time I had an idea rejected that became a new data point that I used to tailor future ideas.

Whatā€™s something people outside the industry might not understand or be surprised to learn about working in coatings?

Waterborne paints are susceptible to spoiling by bacteria whereas solvent-based paints are not. Just because itā€™s waterborne doesnā€™t mean that there arenā€™t any dangerous chemicals present. Biocides are rarely friendly.

What keeps you motivated and eager to come to work each day?

The excitement around the uncertainty about what Iā€™m going to learn, what results my tests are going to produce, what ideas might occur to me, what opportunities or collaborations I might encounter.

Do you have any professional goals that youā€™re still eager to accomplish?

One of my professional goals would be to have my name listed as an inventor on a patent. I have one potentially in the works but Iā€™m going to keep trying until one becomes official.

How does company culture impact your work and ability to perform successfully?

Company culture has had a significant influence on my work. Iā€™ve found that when a companyā€™s culture can trickle down to individual contributors, it tends to have more positive effects. Personally, I find myself happier and eager to go the extra mile when the overall company culture is supported within my immediate teamā€™s culture. My current companyā€™s clear mission, vision, and values help connect corporate culture and team culture. However, in my experience, itā€™s rare for the overall company culture to reach the immediate team level to where the positive effects are felt by the individual contributors. Iā€™ve been at companies where they support an overall culture of innovation but found myself on a team where participating in that culture was deemed a waste of time or even discouraged. Thankfully, thatā€™s not the case at Carlisle.

What opportunities or unique advantages does your company offer that someone new to the workforce or not too familiar with coatings should consider as a career pathway?

I was really impressed with Carlisle when I interviewed. While I havenā€™t been here long, I am realizing how special a company this is. They are incredibly supportive of innovation, which is a key part of Carlisleā€™s Vision 2030 strategy, as well as collaboration between their employees. Employees are encouraged to investigate new concepts and there is even one day each month when they share their discoveries with the team. Iā€™ve had multiple impromptu conversations with coworkers that resulted in us bouncing ideas off each other and leading to future opportunities for collaboration. Carlisleā€™s commitment and follow-through involving investing in their people, innovation, sustainability, and safety stood out to me and I think it is very advantageous.

Is there anything else youā€™d like to share or express that isnā€™t captured in the previous questions?

Iā€™d like to express my gratitude to all those within the coatings community that have not only taken the time to encourage but also teach and support me. I especially thank all those who have been mentors to me, in particular, Mike C., Karen W., Ezekiel B., and Dave B.

Amy Frederick, MLS(ASCP)CM, is a graduate of the University of Cincinnati with a Bachelor of Science in Biology-Microbiology and Cellular Genetics as well as Medical Laboratory Science. Frederick is certified by the American College of Pathologist as a medical laboratory scientist. She entered the world of coatings with the Sherwin-Williams Company on their Performance Coatings Raw Materials team and later worked at Kalcor Coatings Company. Frederick is a scientist at Carlisleā€™s Weatherproofing Technology Division where she works on developing innovative solutions for the roofing restoration industry.

Email: afrederick@henry.com

ĢżReturn to Voices in Coatings: One Industry, Numerous Paths

The increasing adoption of advanced driver assistance systems (ADAS) and autonomous vehicles (AVs) demands highly reliable sensors that can operate effectively in adverse environmental conditions. Fog, rain, mud, and debris accumulation can compromise sensor performance, posing challenges for safe and efficient operation. To address these issues, UV-durable hydrophobic (UVH) coatings designed to improve sensor reliability have been developed.

The effectiveness of UVH coatings was evaluated under both simulated and realworld conditions. The study assessed vision cameras, IR cameras, LiDAR, and radar sensors exposed to various environmental stressors, including fog, rain, mud, insect splatter, and off-road terrain while operating the vehicle at representative speeds. The results demonstrated that UVH coatings effectively reduced environmental contamination on sensors, enhancing imaging, target recognition, and signal clarity, though the impact on LiDAR was less significant.

These findings suggest that UVH coatings can enhance ADAS and AV sensor reliability by reducing maintenance requirements and improving sensor functionality, particularly in wet and debris-prone environments. This article details the coating formulation, testing methodology, results, and broader implications for ADAS and AV systems, highlighting their potential for both commercial and military applications.

Introduction

Advanced driver assistance systems (ADAS) and autonomous vehicles (AVs) depend on a suite of sensors to interpret and navigate the driving environment. Cameras, LiDAR, radar, and infrared sensors provide critical data for object detection, environmental perception, and decision making. However, environmental contaminants such as rain, fog, mud, and debris on sensor covers can significantly degrade sensor performance, potentially compromising both functionality and safety. As a result, maintaining clean and dry sensor surfaces is essential to ensuring the reliability of ADAS and AV technologies.

To address these challenges, several automatic cleaning systems have been developed. For instance, Valeo¹Ģżand Continental²Ģżhave introduced fully automatic cleaning systems that employ retractable liquid-jet nozzles to spray cleaning fluid onto sensor lenses, effectively removing debris. Fordā€™s³ĢżAV development team has designed aerodynamic shields to divert airborne contaminants away from rooftop-mounted LiDAR sensors, reducing the accumulation of dirt and moisture. While these active cleaning solutions enhance sensor reliability, they introduce additional costs related to installation, maintenance, and long-term repairs, making them less desirable for large-scale implementation.

A promising alternative to active cleaning mechanisms is the application of hydrophobic self-cleaning coatings that passively repel water, dirt, and environmental contaminants. Such coatings could significantly reduce the need for frequent cleaning cycles, minimize the consumption of cleaning fluids, and lower overall energy requirements. However, the development of hydrophobic coatings suitable for sensor applications presents several challenges, particularly in achieving high optical transparency while maintaining essential properties such as scratch resistance, UV durability, self-cleaning capabilities, and stain resistance.

Several fabrication methods have been explored to produce transparent nonwettable surfaces, including self-assembly techniques, sol-gel processes, micro-phase separation, templating, and nanoparticle assembly.^{4, 5}ĢżAdditionally, mold transfer methods such as nanoimprint lithography have been employed, utilizing hydrophobic transparent elastomer precursors or UV-induced polymerization.^{6, 7, 8}ĢżSome ceramic precursor-based transparent hydrophobic films have also been proposed for applications in windows and solar energy conversion surfaces.⁹ĢżHowever, many of these techniques lack the mechanical durability and weatherability necessary for long-term use in automotive sensor applications, as they suffer from poor adhesion to substrates and inadequate scratch resistance, leading to rapid degradation under environmental stressors.

To address these limitations, a fluorinated silane-based coating system was developed as a UV-durable hydrophobic (UVH) coating with enhanced UV stability, optical transmission, and mechanical durability. The coating was designed to maintain high hydrophobicity over extended periods while withstanding environmental exposure and mechanical wear. Initial performance validation was conducted in a stationary testbed under simulated weathering conditions, including fog, rain, mud, and insect splatter, confirming both the coatingā€™s durability and its ability to improve sensor performance.¹⁰ĢżTo further evaluate real-world effectiveness, PPG Industries, Inc., in collaboration with the Nevada Automotive Test Center (NATC), conducted comprehensive field tests. The results demonstrated that UVH coatings significantly enhanced sensor clarity and functionality, reinforcing their potential as a cost-effective and durable alternative to active sensor cleaning systems.

Experimental Design

UV-Durable Hydrophobic (UVH) Coatings

Hard coat-coated borosilicate glass, as well as hard-coated polycarbonate (PC) and silicon substrates, were pretreated with air plasma for 15 min using an ATTOā„¢ plasma treater (Diener Electronics, Germany). Proprietary UVH coatings, formulated with fluorinated silane from PPG Industries, Inc., were subsequently applied to the pretreated substrates via an ultrasonic spray coating technique. The coatings were deposited using a Prism Ultra-Coat ultrasonic spray system (Ultrasonic Systems, Inc., Haverhill, MA).

The coated samples were cured at 100 Ā°C for a duration of 10 to 15 min. Post-curing, the static water contact angle (sWCA) was measured by placing three 2.0 Ī¼L droplets of deionized water onto the surface of each sample using Kruss Drop Shape Analyzer DSA100. The average sWCA was determined using ADVANCE software in conjunction with a Kruss Drop Shape Analyzer DSA100 Instrument. Due to the inherent hydrophobic properties of the UVH coatings, the sWCA was measured to be 115Ā° Ā± 1Ā°.

Automotive manufacturers are increasingly interested in drop-ondemand (DOD) inkjet technology for its potential to enable high-resolution, on-demand customization while improving paint shop efficiency and sustainability. Compared to traditional spray application methods, DOD technology offers significant benefits in reducing volatile organic compound (VOC) emissions, minimizing paint waste, and eliminating the need for masking and demasking processes. However, applying automotive coatings via DOD presents unique challenges due to the high solids content, viscosity, and shear-thinning behavior required for environmental compliance, application feasibility, and appearance quality.

Unlike conventional inkjet inks, which are Newtonian and low viscosity (<20 cP), automotive paints require specialized formulation and process adaptations to ensure reliable jetting. This article explores the integration of piezoelectric DOD technology with a circulation system to address key challenges such as maintaining jetting stability, achieving clean droplet break-off, preventing nozzle drying, and controlling undesirable wetting behavior. Here, we demonstrate successful jetting of waterborne and solventborne automotive coatings, highlighting the role of rheological control, droplet throw distance management, and defect mitigation strategies. Through collaboration with industry partners, these key learnings were implemented in trials printing on an automotive body. Results confirm the feasibility of this approach for OEM-scale implementation, bringing DOD technology closer to practical automotive manufacturing applications.

Introduction

The demand for personalized car designs has been increasing in recent years, with the “Tutone” two-tone color scheme (Figure 1a) experiencing a resurgence. This design, popular in the 1950s, has made a comeback as customers are willing to pay a premium for customization.¹ However, manufacturing a Tutone vehicle presents several challenges, including increased volatile organic compound (VOC) emissions from additional paint consumption, waste from masking and demasking, higher labor costs, and a more complex, time-consuming production process.

Another popular but currently non-OEM-compatible customization method is graphic design (Figure 1b) or even logos. This is typically achieved using decals, which are labor-intensive to apply. More intricate graphic designs are executed using vinyl wraps.

Drop-on-demand (DOD) inkjet technology has been used for complex graphics for years, and, in 2022, Boeing demonstrated its potential on the 737 Max 9.² Given this precedent, can a similar approach be applied to the automotive industry? The answer is yes, but with key differences. Inkjet printing traditionally relies on depositing individual pixels of cyan, magenta, yellow, and black inks. Such an approach does not result in a continuous protective coating required for automotive application.

OEM-Compatible Processes for DOD

Figure 2a illustrates how current Tutone vehicles are manufactured and the masking and demasking steps are wasteful and labor intensive. With DOD, we propose two OEM-compatible options: one in-line and one end-of line process (Figure 2b). Both would work for Tutone as well as graphic designs.

FIGURE 1 Examples of Tutone (a) and graphic (b) design.

FIGURE 2 (a) Current OEM process for Tutone vehicles. (b) Proposed in-line and end-of-line processes.

Piezoelectric DOD Inkjet and Circulation System

DOD technology generates droplets only when needed, achieved through various methods. Common techniques include (1) thermal, which is suitable only for waterborne (WB) inks; (2) valvejet, which offers low resolution and flow rate; and (3) piezoelectric, which is compatible with both WB and solventborne (SB) formulations and is the preferred method.³

In piezoelectric DOD, the printhead walls are composed of piezoelectric materials that deform when a voltage is applied.⁴ This deformation generates a pressure wave that ejects a droplet from the chamber behind the nozzles. We found that combining piezoelectric DOD with a circulation system significantly enhances paint jetting performance.

Figure 3 presents the system diagram. The paint circulates between the reservoir and printhead, driven by two pumps. A differential pressure of approximately 100ā€“200 mbar is maintained to ensure a consistent flow rate, keeping the printhead chamber adequately supplied. A final-stage filter is installed before the printhead to capture large particles that could clog nozzles and channels. A mild negative pressure (meniscus pressure) of approximately -10 to -20 mbar at the nozzle prevents paint oozing and nozzle plate flooding while still allowing droplet ejection when triggered by the piezo-induced pressure wave. Precise and stable control of paint supply and meniscus pressure of the printhead is critical to good jetting.

FIGURE 3 Piezoelectric DOD with circulation system. (a) Setup of circulation system. (b) Cross section of the printhead to illustrate the paint circulating behind the nozzles.

Shear Rate Considerations

Paint experiences a wide range of shear rates throughout the system. Shear rate is near zero in the reservoir, around 100 sā€“1 in tubing, increases to āˆ¼10,000 sā€“1 in printhead channels, and reaches āˆ¼100,000 sā€“1 or higher at the nozzles (10ā€“50 Ī¼m in diameter). Traditional piezo DOD inks are low-solids, low-viscosity (<20 mPaĀ·s), and Newtonian, whereas paints have significantly higher solids content, viscosity, and exhibit shear-thinning behavior.

Figure 4 illustrates shear rates at various locations and presents examples of jettable WB formulations. Unlike inks, paints require higher pressure to achieve comparable flow rates due to their higher viscosity. Additionally, shear-thinning paints are often thixotropic. Without a circulation system, inkjet operation involves on-off cycles, leading to fluctuations in viscosity, pump demand, and system pressure, which can negatively impact jetting quality. Continuous circulation mitigates these fluctuations, stabilizing jetting performance while preventing aggregate and air bubble formation. Since automotive paints often contain fast-drying solvents, circulation also prevents nozzle drying.

Shortly after publication of “The State of the U.S. Paint and Coatings Industry: Geopolitics, Supply Chains, and Strategy” in the , we became aware that the adjustment of certain values would be necessary. ChemQuestā€™s “numbers” are refined and adjusted on an ongoing basis, which typically allows us to view the specialty chemical markets in a relatively seamless fashion without being thrown offcourse by minor blips in the performance of any given sector. Between the date of submission of the article and its publication, however, company reports for the U.S. paint and coatings market were published for second quarter results and displayed a wholly uncharacteristic slump in performance. While there are many theories regarding why this happenedā€”tariffs and/or fear of tariffs; concerns about the bourgeoning national debt; the significant increase in global tensions with the failure to make progress toward peace in the Russo-Ukrainian War; the attack on Iran by Israel and the U.S.; and many other geopolitical concernsā€”it is far from clear what the specific causal factors are for the drop in production.

Regardless, the performance slump was very real and has convinced ChemQuest that a restatement of growth rates in certain sectors of both the specialty chemicals market space, as well as the paint and coatings segment within that market space, is appropriate. We are living in an unusually dynamic, and therefore volatile, period in modern history and must recognize that all global supply chains either have been, or will be, negatively affected as a result. With our thanks for your understanding and a mutual desire for up-to-date data, please note the following adjustments (figure numbers correspond to those in the original November/December publication).

FIGURE 3 U.S. paint and coatings industry, by volume and value (2020-2026f).

FIGURE 7 U.S. architectural coatings market segment, by volume and value (2020-2026f).

FIGURE 12 U.S. industrial OEM coatings, by volume and value (2020-2026f).

FIGURE 16 U.S. special purpose coatings, by volume and value (2020-2026f).

U.S. Coatings Market, 2025e

• Volume decrease of 0.8% (vs 1.1% increase)
• Value increase of 1.1% (vs 2.9%)

Architectural Paints

• 2025e volume decrease of 2.5% (vs 0.3% increase)
• 2025e value decrease of 0.9% (vs 1.3% increase)
• 2026f volume increase of 1.7% (vs 1.9%); value increase remains 3.9%

Industrial OEM, 2025e

• Value increase of 3.5% (vs 4.4%)
• Volume increase of 1.4% (vs 2.2%)

Special Purpose Coatings

• 2025e value increase of 3.7% (vs 4.2%)
• 2025e volume increase of 2.1% (vs 2.4%)
• 2026f value increase 5.4% (vs 5.9%)
• 2026f volume increase of 2.5% (vs 2.8%)

Automotive Refinish Coatings

• 2025e value increase of 3.2% (vs 4.4%)
• 2025e volume increase of 1.2% (vs 2.6%)
• 2026f value increase of 5.5% (vs 6.6%)
• 2026f volume increase of 2.4% (vs 2.3%)

Outlook for U.S. Coatings Market, 2026f

• Volume increase of 1.8% (vs 2.1%)
• Value increase of 4.4% (vs 4.9%)

Please reach out to the author at gpilcher@chemquest.com for additional information or further clarification.