As U.S. regulators and state governments continue expanding restrictions on per- and polyfluoroalkyl substances (PFAS), manufacturers are increasingly exploring technologies that could reduce reliance on the chemicals commonly known as “forever chemicals.” Among the emerging alternatives are femtosecond lasers, which can modify material surfaces without requiring fluorinated coatings.
The growing regulatory focus comes as at least 31 states are expected to consider policies addressing PFAS this year, according to the Safer States alliance. Proposed measures include product bans, drinking water standards, restrictions on sludge spreading, and funding for environmental cleanup. States such as Maine, Minnesota, and New Mexico have introduced some of the broadest approaches by pursuing wider limits on products containing intentionally added PFAS.
PFAS have long been used across industries because of their resistance to heat, corrosion, water, oil, and stains. The chemicals are found in a broad range of consumer and industrial products, including cosmetics, toys, furniture, and textiles. However, growing scientific and regulatory concerns have linked PFAS exposure to increased risks of cancer, liver and kidney disease, developmental issues in children, and other health problems, prompting governments and manufacturers to seek alternatives.
According to LITILIT, a startup that manufactures femtosecond laser systems, ultrashort-pulse laser technology could provide one such alternative by creating water-repellent surfaces through physical texturing rather than chemical coatings.
Nikolajus Gavrilinas, the company’s chief executive officer, said the technology offers manufacturers a different approach to achieving water-resistant surfaces.
“PFAS coatings are widely used to repel water, oil, and stains, but femtosecond lasers offer another route: they can texture surfaces at micro- and nano-scale to make materials water-repellent without applying a fluorinated coating. It’s an approach that applies anywhere water, ice or corrosion are a problem – from building materials and stone to metal, glass and everyday interior products,” he explains.
Femtosecond lasers emit pulses lasting only a quadrillionth of a second, allowing them to reshape a material’s surface before heat can spread into the surrounding area. This process creates microscopic and nanoscopic textures that alter surface properties without damaging the material itself, making it possible to produce water-repellent finishes without applying fluorinated chemicals.
Gavrilinas said the technology has applications beyond replacing PFAS coatings. According to the company, ultrashort laser pulses can replace certain chemical-based processes across a variety of manufacturing sectors, including consumer electronics, furniture, and interior design. Decorative metal elements, handles, and fittings, for example, can be given color through laser texturing instead of paints or inks.
While the technology has gained attention for its potential environmental benefits, scaling production remains one of the industry’s biggest challenges. Gavrilinas said manufacturing capacity has not kept pace with increasing demand for femtosecond laser systems.
To address that gap, LITILIT has begun construction of a new manufacturing facility in Vilnius that is expected to produce up to 3,000 femtosecond lasers annually. The company said the plant would rank among the highest-capacity femtosecond laser production facilities in the world.
LITILIT also said its laser systems are based on patented technologies developed by company co-founders Kęstutis Regelskis, Nerijus Rusteika, and Gavrilinas in collaboration with the Center for Physical Sciences and Technology (FTMC) in Vilnius.
As environmental regulations continue to evolve, manufacturers are expected to evaluate new production technologies that can reduce reliance on persistent chemicals while maintaining product performance.
Gavrilinas said making alternative manufacturing tools practical and accessible for industrial use will be essential to accelerating the transition away from PFAS.
“Manufacturers cannot move away from toxic chemicals at scale if the alternative tools remain expensive, complex and difficult to integrate. That is why we are focused not only on making femtosecond lasers work, but on making them easier to produce, easier to install and easier to use in real factories,” Gavrilinas says.
Industry experts say innovations in laser-based manufacturing could play an increasingly important role as companies seek sustainable production methods that align with stricter environmental standards while reducing dependence on long-lasting chemical coatings.
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