Outlast integrates aerogel into fabrics for space-saving insulation

Aerogel is an ultra-lightweight, highly porous material derived from quartz - the same base substance found in sand. Despite its low density, it offers excellent thermal insulation properties by trapping air within its pore structure. Originally used in aerospace applications, aerogel’s fragile and powdery nature has long made it difficult to process in textiles.

Outlast Technologies has succeeded in integrating aerogel into flexible fabric systems through a series of engineered composite structures now offered under the name Aersulate. These materials provide reliable thermal insulation even in extremely thin formats and under compression or moisture exposure.

“One of the biggest challenges was simply getting the material to stay where we wanted it,” says Volker Schuster, Head of Research and Development. “Due to its incredible lightness, aerogel tends to disperse into the air instantly unless it is bound immediately - which, as you can imagine, was no trivial task.”

Reliable Insulation at 1–2 mm Thickness

Aersulate fabrics function with a material thickness of just 1-2 millimeters - comparable to a credit card - yet reach insulation levels that match or exceed those of conventional, much thicker insulations. This space efficiency opens up new possibilities in areas where insulation was previously not feasible due to volume, weight, or processing constraints.

Unlike felts, waddings, or fleeces, Aersulate retains its insulating performance even under pressure. While conventional insulations often lose effectiveness when compressed, the aerogel structure embedded in Aersulate continues to trap air, preventing thermal transfer.

Additionally, the material’s thermal resistance is not significantly affected by humidity. “In typical materials, moist conditions often lead to heat leakage,” explains Schuster. “With Aersulate, the air within the aerogel structure stays in place und nearly completely keeps up the performance.”

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ALCHEMPro News Desk (HU)