Where is PFAS hiding in your car?

As discussed in our blog on the PFAS contamination problem, PFAS are facing increasing regulatory and public scrutiny due to their persistence and potential impacts on human health and the environment. 

Replacing PFAS is often challenging because they’re deeply embedded within vehicle designs and manufacturing processes. In many applications, no single alternative can deliver the same performance, meaning manufacturers may need to combine multiple materials or redesign components entirely. 

As regulatory scrutiny increases, automotive manufacturers and suppliers are taking a closer look at where PFAS are used throughout vehicles, assessing the risks associated with their continued use and exploring alternative materials that can deliver the required performance. 

Where to find PFAS in your car

PFAS can be in interiors, under-the-hood parts and inside electric vehicle (EV) batteries. 

• Interior fabrics: Stain and water-repellent coatings on seats and carpets. 

• Dashboard and interior coatings: Heat-resistant coatings and materials that help maintain durability and performance under prolonged exposure to sunlight and elevated cabin temperatures. 

• Paints and coatings: Special coatings used to create weather-proof surfaces or lower friction as well as in waxes and polishes for repelling water and dirt. 

• Seals, gaskets and hoses Fluoropolymers (e.g. PTFE and fluoroelastomers) are commonly used in fuel system seals, O‑rings, engine and battery cooling system gaskets, and fluid transfer hoses because of their exceptional resistance to heat, chemicals and fuels 

• Lubricants: PFAS are used in specialty greases and lubricants for bearings, actuators and other components operating under high temperatures or corrosive conditions. 

• Wiring: PFAS are used for heat resistance and electrical insulation in cables and wiring. 

• Brake systems: Specialty brake linings and hydraulic fluids. 

• Tyres: Fluorinated processing aids and additives have historically been used in some rubber formulations. Compared with applications such as batteries, seals and wire insulation, PFAS use in tyres is relatively limited. 

• Electric vehicle (EV) batteries: PFAS, particularly Polyvinylidene Fluoride (PVDF), are widely used as cathode binders in battery electrodes because they provide excellent chemical stability and adhesion. Other fluorinated materials are also used in some battery components and electrolytes. However, these materials can make battery recycling more challenging and are driving research into fluorine-free binders and electrolyte chemistries. 

The regulatory landscape

Regulation is becoming one of the biggest drivers of PFAS substitution in automotive applications. In Europe, authorities have proposed a broad restriction on around 10,000 PFAS substances under the REACH Regulation, making it one of the most significant chemicals restrictions ever considered in the EU. The proposal spans numerous industrial sectors, including automotive materials and components. 

While the proposal includes temporary exemptions for certain essential uses where no suitable alternatives exist, many applications would face relatively short transition periods where substitutes are already available. For more challenging applications, these temporary exemptions are intended to provide time for innovation rather than a route towards permanent exemption. 

With the European Chemicals Agency (ECHA) expected to conclude its scientific evaluation by the end of 2026, many automotive manufacturers and suppliers are already mapping PFAS across their supply chains, assessing substitution priorities and accelerating the development of alternative materials ahead of future regulatory requirements. 

While there are currently no UK regulations or policies specific to PFAS in automotive applications, the direction of travel is clear. The UK government has set out its approach to PFAS risks through policy. The PFAS Plan outlines steps to understand PFAS sources, tackle PFAS pathways, and reduce ongoing exposure to PFAS through collaboration and partnership with industry and other bodies. The government aims to support industry by creating a regulatory environment that fosters innovation and investment, providing opportunities to tap into the PFAS-free market, which was estimated to reach $14.9 billion annually in the EU by 2040. 

Recent innovations and PFAS replacements

The automotive industry’s response to PFAS is pragmatic. Straight replacements are rare, so recent efforts combine new polymers, reformulated chemistries and design/​process adjustments. 

PFAS-free coatings are being developed by manufacturers as PFAS-free paints, coatings and surface treatments using alternative polymer chemistries, silicone- and silane-based materials, and engineered surface textures to deliver properties such as water repellence, corrosion resistance and reduced friction without relying on fluorinated compounds. 

Where performance (temperature, chemical resistance, low friction) is needed, high-performance thermoplastics such as polyether ether ketone (PEEK), polyphenylene sulfide (PPS) and reinforced nylons are being evaluated by companies as substitutes for PFAS in parts and seals. These materials often require design or processing changes. 

Sealing and gasket innovations are focused on developing PFAS-free seals and gaskets by replacing fluoroelastomers with alternative materials such as hydrogenated nitrile butadiene rubber, ethylene propylene diene monomer and silicone elastomers. These materials, combined with optimised seal designs and engineered fillers, aim to deliver the heat resistance, chemical compatibility and durability required for demanding automotive applications. 

Battery research is focused on replacing polyvinylidene fluoride (PVDF) binders with fluorine-free alternatives and developing next-generation fluorine-free electrolyte chemistries. While several promising binder materials have demonstrated electrochemical performance comparable to PVDF at laboratory scale, challenges remain around manufacturing compatibility, cost, long-term durability and commercial scale-up. 

Understanding where PFAS are used is often the first step towards substitution, making detection and supply-chain mapping increasingly important. Automotive manufacturers are increasingly combining advanced analytical testing with supply-chain mapping to identify PFAS-containing materials, assess regulatory risk and prioritise replacement strategies. 

Who’s leading the way

While no single solution will replace PFAS across all automotive applications, a growing ecosystem of companies is developing alternatives spanning coated textiles, seals, surface treatments and battery materials. 

Renegade Plastics (USA) develops polypropylene-based, industrial-grade coated fabrics that are free from PFAS and designed to match the performance of traditional coated textiles. 

In battery and solar applications, Westra Materials (Sweden) develops PFAS-free, thermally stable and conductive polymers for electric vehicle batteries and solar panels. The company secured SEK 42 million in October 2025 to support production scale-up. 

Nanoramic (USA) has developed its Neocarbonix electrode technology, which functions as both a binder and conductive additive, eliminating the need for PFAS binders. 

For demanding sealing applications, Omniseal Solutions (USA) develops PFAS-free precision sealing solutions for demanding applications across sectors including aerospace, aviation, life sciences and industrial equipment. 

Within surface treatment, SurTec (Germany) develops and supplies PFAS-free functional coatings, anti-friction coatings and sealing solutions as part of its surface treatment portfolio. 

Ateios Systems (USA) is developing innovative electrode manufacturing technologies using PFAS-free binders. 

Current challenges in replacing PFAS

Material performance and application redesign
PFAS have historically been selected because they offer a versatile combination of properties. The challenge in replacement is understanding the specific performance requirements of each application and identifying alternative materials or designs that deliver the necessary functionality without compromising safety, durability or cost. 

Battery performance and safety
Even small material changes can affect battery cycle life, safety and manufacturing yields, making manufacturers cautious about replacing polyvinylidene fluoride (PVDF) in battery components. 

Upstream emissions and waste streams
PFAS can be released during production and disposal, prompting manufacturers to consider the full lifecycle of materials and manufacturing processes, not just the finished vehicle. 

Qualification timelines
Automotive materials often take several years to qualify due to stringent safety, durability and performance requirements. As a result, even technically proven PFAS alternatives can take considerable time to reach commercial deployment. 

The future of PFAS in automotive

Global regulation is expected to accelerate PFAS phase-outs. While alternatives are emerging across many automotive applications, their adoption will depend on whether they can be produced at sufficient scale, meet demanding performance requirements and achieve cost competitiveness. Companies are therefore likely to prioritise substitution where alternatives are readily available, while more challenging applications may require longer transition periods and further materials innovation. 

Future innovation will extend beyond direct material replacement. Opportunities include the development of new polymers and formulations, surface engineering approaches that deliver water repellence and low-friction performance without fluorinated chemistries, and redesigned components that reduce reliance on PFAS-containing materials. 

For electric vehicles, PFAS replacement is also becoming increasingly important as battery manufacturing scales. PVDF binders are widely used in lithium-ion electrodes due to their stability and adhesion, but fluorinated materials can create additional challenges during battery recycling and end-of-life processing. Developing fluorine-free binders and alternative battery materials could support improved circularity while maintaining battery performance. 

The transition away from PFAS represents a significant opportunity for materials innovation across the automotive supply chain. Advances in polymer synthesis, formulation, coatings, tribology and surface engineering will be critical to developing solutions that deliver the required performance, durability and sustainability for next-generation vehicles.

How CPI can help

Replacing PFAS in automotive applications requires more than simply identifying alternative materials. It demands a detailed understanding of material performance, manufacturing processes, regulatory requirements and commercial viability. At CPI, we work with innovators across the automotive value chain to develop and scale sustainable material solutions, supporting everything from polymer development and formulation to coatings, surface engineering and advanced manufacturing processes. 

Our experts help organisations identify where PFAS are used within products and processes, characterise material performance requirements and assess opportunities for substitution. We develop, modify and optimise polymer systems to deliver the performance needed for demanding automotive applications, while designing alternative coatings and surface treatments that provide durability, reduced friction, water repellence and chemical resistance without relying on fluorinated chemistries. 

Beyond materials development, we help bridge the gap between laboratory innovation and industrial production. Through pilot-scale process development, advanced analytical characterisation and process optimisation, we support companies in scaling promising technologies with greater confidence. We also use modelling, life cycle assessment (LCA) and techno-economic analysis (TEA) to evaluate environmental impact, scalability and commercial viability, enabling informed decision-making throughout development. 

From bespoke pilot-scale manufacturing processes to end-to-end commercialisation support, CPI helps businesses accelerate the development of next-generation automotive materials and bring viable PFAS alternatives closer to market. 

Towards a PFAS-free automotive sector

PFAS are deeply embedded within automotive supply chains, from stain-resistant interiors and surface treatments to critical components such as seals, wiring and battery materials. While complete substitution won’t happen overnight, the direction of travel is clear. Increasing regulation, growing sustainability expectations and advances in materials science are accelerating the development of PFAS-free solutions. 

The transition presents significant opportunities for innovators developing next-generation polymers, coatings, formulations and engineered surfaces that deliver the performance required by modern vehicles. Companies that begin understanding their PFAS footprint, identifying critical material requirements and investing in alternatives today will be better positioned to meet future regulatory requirements and capture value in the next generation of sustainable automotive materials.