Enhanced ptfe-free mold release via laser-textured silicone-coated molds
A novel mold release technology combining laser-textured microscale surface features with food-contact-approved non-PTFE silicone coatings to achieve PTFE-equivalent release performance for polymer thermoforming applications.
Overview
This technology addresses the growing regulatory and environmental pressure to eliminate PTFE (polytetrafluoroethylene) from industrial mold release applications. By combining laser-textured microscale surface features with non-PTFE silicone coatings, the approach aims to deliver release performance comparable to traditional PTFE-based agents while remaining compliant with food-contact safety standards. The dual-mechanism strategy targets both the physical and chemical factors that cause polymer adhesion to mold surfaces, offering a drop-in alternative for manufacturers seeking to phase out fluorinated compounds.
Technical specifications
Key features:
- Laser-textured microscale repeating features on mold surfaces reduce friction and contact area at the polymer-metal interface
- Non-PTFE silicone release coatings create an additional energy barrier to adhesion between the polymer part and the mold
- Food-contact-approved silicone agents suitable for PET thermoforming and related polymer processing
- Aerosol jet printing enables precise, uniform coating deposition on textured mold surfaces
- Pulsed laser processing for creating reproducible microstructures on metal mold substrates
- Peel-test-validated adhesion energy quantification for coating selection and optimization
Technology readiness level
The technology is currently at an early-to-mid stage of development. Future validation will include computational modeling of polymer flow over textured surfaces to identify optimal texture geometries, systematic peel testing of various silicone coating thicknesses and formulations on planar metal substrates, and end-to-end demonstration using laser-textured molds with aerosol jet-printed coatings for PET thermoforming trials. This staged approach is designed to move the technology from laboratory validation toward prototype-ready mold surface treatments suitable for pilot-scale evaluation in industrial thermoforming operations.
About Rutgers University
Rutgers University is a comprehensive public research university and New Jersey’s flagship, spanning campuses in New Brunswick–Piscataway, Newark, and Camden. For industry, it offers an integrated clinical and biomedical enterprise through its health system, a statewide extension network for field deployment, and campus-based incubators and pilot-scale facilities that enable prototyping and scale-up. Companies engage through sponsored research, shared core facilities, professional education, and flexible partnership models supported by corporate engagement teams. Research is supported by competitive federal funding from agencies such as NIH, NSF, DOE, and USDA. A dedicated technology transfer office manages IP, licensing, material transfer, and startup formation, providing clear pathways from lab discovery to market.
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