Carbon Fiber & Materials
Aerogel Insulation: The Space-Age Material You Can Actually Buy
What silica aerogel is, why it is one of the best thermal insulators on Earth, and practical uses from EV battery packs to workshops.
· 6 min read
Key takeaways
- Aerogel is mostly air trapped in a nano-porous silica structure.
- Its thermal conductivity is far lower than typical foam or fibreglass.
- Flexible blankets make it usable in real projects.
- Common uses: battery thermal barriers, pipes, enclosures, outdoor gear.
What is aerogel?
Aerogel is made by replacing the liquid in a gel with gas without collapsing the structure. The result is a solid that is up to 99% air, with pores so small that heat has a very hard time moving through it.
Rigid aerogel is fragile, so industry uses aerogel blankets: fibre mats impregnated with aerogel that can be cut, wrapped and bent.
Why it insulates so well
Heat travels by conduction, convection and radiation. Aerogel's nano-pores block convection and its tiny solid fraction limits conduction, giving it extremely low thermal conductivity in a thin layer.
Practical uses
Because a thin layer does the work of a much thicker conventional insulator, aerogel shines where space is tight.
- Thermal barriers between battery cells
- Insulating 3D-printer enclosures and hot ends
- Pipe and duct insulation
- Camping and cold-weather gear
Pro tip: Cut aerogel blankets outdoors or with a mask — they shed fine dust.
Frequently asked questions
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