MouldTex · Project

Laser-Textured Moulds That Cut Seal Friction by 20% at Minimal Extra Cost

manufacturingPilotedTRL 7

Rubber seals are everywhere — in car engines, hydraulic cylinders, factory pumps. When they rub too hard, they wear out fast, leak, and waste energy. This project figured out how to engrave tiny patterns onto the moulds that make these seals, so every seal that comes out already has a friction-reducing texture built in. Think of it like the dimples on a golf ball — tiny surface features that change how things move — except here they're laser-carved into the mould itself, so millions of seals get the benefit automatically.

By the numbers

>20%

Friction reduction target for textured seals

<10%

Cost premium over conventional mould production

Pilot lines established (mould tools, rotary seals, reciprocating seals)

Consortium partners

Countries represented in consortium

SME partners in the consortium

Axis laser system fully operational

The business problem

What needed solving

Polymeric seals in engines, hydraulic cylinders, and industrial equipment wear out prematurely because of friction, leading to leaks, costly downtime, and wasted energy. Current manufacturing methods produce smooth seal surfaces that do nothing to manage friction. Manufacturers need a way to build friction-reducing features directly into seals during mass production — without blowing up their tooling costs.

The solution

What was built

The project built a fully operational 5-axis laser system with adaptive optics and Raptor Laser Cam software for engraving nanotextures onto mould surfaces, plus advanced modelling software to design optimal texture patterns for specific seal applications. Three pilot lines were demonstrated: mould tool production, rotary engine seals, and reciprocating industrial seals, with inline optical inspection for quality control.

Audience

Who needs this

Seal manufacturers (rotary and reciprocating seals for automotive and industrial use)Mould and tool makers serving the rubber/plastics industryAutomotive Tier 1-2 suppliers of engine gaskets and sealing systemsHydraulics and pneumatics equipment manufacturersIndustrial pump and valve producers dealing with seal failure

Business applications

Who can put this to work

Automotive components

mid-size

Target: Seal manufacturers supplying engine and powertrain components

If you are a seal manufacturer supplying rotary seals for engine applications and dealing with warranty claims from premature seal wear — this project developed a laser-textured mould process that achieves friction reduction of >20% at a cost premium of <10%. The pilot line for rotary engine seals was fully demonstrated, meaning the technology is ready for integration into existing moulding operations.

Hydraulics and pneumatics

SME

Target: Manufacturers of reciprocating seals for industrial cylinders and pumps

If you are a hydraulics equipment maker struggling with seal-related energy losses and maintenance downtime — this project built and demonstrated a pilot line specifically for reciprocating seals used in industrial processes. The laser texturing reduces friction by >20%, which directly translates to lower energy consumption and longer seal life in your hydraulic and pneumatic systems.

Mould and tool making

SME

Target: Precision mould tool manufacturers serving the rubber and plastics industry

If you are a mould tool manufacturer looking for a competitive edge — this project developed a fully operational 5-axis laser system with adaptive optics and dedicated software (Raptor Laser Cam) for engraving nanotextures onto mould surfaces. A dedicated pilot line for mould tool design and manufacture was demonstrated, giving you a new high-value service to offer your customers.

Frequently asked

Quick answers

What would it cost to add this texturing to our existing moulds?

The project targeted a cost premium of less than 10% over conventional mould production. This means if your current mould costs €10,000, the textured version should stay under €11,000. Exact pricing would depend on seal geometry and texture complexity.

Can this work at industrial production volumes?

Yes. The project established three pilot lines — one for mould tool manufacture, one for rotary engine seals, and one for reciprocating industrial seals. The fully operational 5-axis laser system was designed for high-volume manufacture, not just lab samples.

How do we access this technology — is it patented or licensable?

The project was an RIA (Research and Innovation Action) with 10 consortium partners across 7 countries. IP arrangements would need to be discussed with the consortium, likely through the coordinator INSTITUTO TECNOLOGICO DE ARAGON in Spain. The 5 industrial partners and 5 SMEs in the consortium may already hold licenses for specific applications.

Does this work with our specific seal materials and designs?

The project developed advanced modelling software that identifies optimal surface texture patterns for specific rubber and plastic seals tailored to their operating environment. This means the texturing is not one-size-fits-all — it can be customized to your materials and friction conditions.

How do we verify the quality of textured seals in production?

The project included inline optical inspection for surface texture pattern quality control as part of its methodology. This means quality assurance is built into the production process, not just a post-production check.

Is the technology proven beyond laboratory conditions?

The project moved well beyond the lab. Pilot line demonstration events were organized for seal manufacturers and mould tool manufacturers across a broad European network. The 5-axis laser system met its target KPIs in operational conditions.

Consortium

Who built it

The MouldTex consortium is well-balanced for industrial uptake: 10 partners across 7 countries (DE, EL, ES, FR, HU, IL, IT) with a 50% industry ratio and 5 SMEs. This means half the consortium are companies that need this technology to work commercially, not just academically. The mix includes 5 industrial partners, 2 research organizations, 1 university, and 2 others — coordinated by INSTITUTO TECNOLOGICO DE ARAGON, a Spanish technology institute with applied research focus. The strong SME presence suggests the technology was designed with smaller manufacturers in mind, not just large automotive OEMs.

INSTITUTO TECNOLOGICO DE ARAGONCoordinator · ES
POLYMERISparticipant · FR
ORP STAMPI SRLparticipant · IT
IDRYMA TECHNOLOGIAS KAI EREVNASparticipant · EL
FUNDACION TECNOLOGICA ADVANTXparticipant · ES
ML ENGRAVING SRLparticipant · IT
INSPIRALIA SOCIEDAD LIMITADAparticipant · ES
SKM AERONAUTICS LTDparticipant · IL
GOTTFRIED WILHELM LEIBNIZ UNIVERSITAET HANNOVERparticipant · DE

How to reach the team

Coordinator is INSTITUTO TECNOLOGICO DE ARAGON (Spain) — a technology institute focused on applied industrial research. Contact can be found via their institutional website or project page.

Order a report on this consortium See INSTITUTO TECNOLOGICO DE ARAGON profile →

Next steps

Talk to the team behind this work.

Want an introduction to the MouldTex team to discuss licensing the laser texturing process for your moulds? SciTransfer can arrange a direct meeting with the right technical contact.

Order a report on this topic More in Manufacturing & Industry 4.0