Next-generation fluorocarbon-free superhydrophobic coatings for medical protective textiles and personal protective equipment

The increasing environmental and regulatory concerns associated with per- and polyfluoroalkyl substances (PFAS) have accelerated research into fluorocarbon-free repellent technologies for medical protective textiles and PPE (Personal Protective Equipment). Polypropylene (PP) nonwovens, widely used in masks, gowns, and other protective equipment, inherently provide hydrophobicity but lack oleophobicity and chemical resistance, necessitating surface functionalization. Recent advances in PFAS-free coatings, including silicone-based, hydrocarbon, and hyperbranched dendrimer chemistries, demonstrate effective water repellency and partial barrier performance through micro/nanoscale surface structuring. Plasma-assisted deposition and pre-treatment methods improve adhesion and conformal coating without compromising filtration efficiency. However, PFAS-free finishes face critical limitations: reduced resistance to oils and biological fluids, weak adhesion to chemically inert PP, and significant degradation after repeated laundering or sterilization cycles. Water contact angle measurements indicate thinning, cracking, and partial delamination, highlighting the gap in durability compared to traditional PFAS-based finishes. Despite these challenges, PFAS-free finishes show promise for low- to moderate-risk applications, emphasizing sustainability and reduced toxicity. Achieving durable, multifunctional, and reusable PPE requires advanced material strategies, including hybrid coatings, bio-inspired surfaces, and nanostructured functional layers. This review critically evaluates current developments, performance limitations, and prospective strategies for the translation of fluorocarbon-free repellent technologies into safe, sustainable, and high-performance medical PPE.