Aerogel Insulation
An ultra-lightweight, nanoporous silica-based insulation material offering the lowest thermal conductivity of any solid material, used in automotive thermal management, EV battery insulation, and exhaust heat shielding.
Overview
Aerogel is one of the most remarkable materials in modern engineering — a solid foam with up to 99.98% air by volume, derived from a gel in which the liquid component has been replaced with gas. Silica aerogel has the lowest thermal conductivity of any known solid (as low as 0.015 W/m·K, lower than still air), making it an extraordinary insulator. In automotive applications, aerogel panels, blankets, and coatings are used wherever extreme thermal insulation in minimal space is required. In electric vehicles, aerogel is increasingly used as a thermal barrier between battery cells and modules to prevent thermal runaway propagation — a critical safety function. It is also used in exhaust heat shields, catalytic converter insulation, underbody thermal barriers, and cabin climate control insulation. Aerogel composites (aerogel particles embedded in polymer or fibre matrices) are more robust than pure aerogel and are the preferred form for automotive applications. Leading suppliers include Aspen Aerogels, BASF (Slentite), and Cabot. Cost has historically been a barrier to broad adoption, but prices are falling as EV battery thermal management requirements drive demand growth.
Automotive Applications
Similar Materials
Thermoelectric Materials
Energy Harvesting Material
Semiconductor materials that convert temperature differentials directly into electrical energy, enabling waste heat recovery in automotive powertrains.
Polyimides
High-Performance Polymer
A class of ultra-high-temperature resistant polymers offering outstanding thermal stability, mechanical properties, and chemical resistance for extreme automotive environments.
Basalt Fibre Composites
Mineral Fibre Composite
Mineral-fibre composites based on basalt, used as a glass-adjacent reinforcement with a different sustainability and temperature story.
Glass Fibre Reinforced Polymer (GFRP)
Glass Fibre Reinforced Polymer
A composite material consisting of a polymer matrix reinforced with fine glass fibers for enhanced structural properties.
Properties
Category
Type
Nanoporous Insulation Material
Available Colors
Available Forms
Key Properties
- Lowest thermal conductivity of any solid (~0.015 W/m·K)
- Ultra-lightweight (up to 99.98% air)
- Excellent fire resistance
- Hydrophobic (surface-treated grades)
- Very low density
- Maintains performance across wide temperature range
- Critical EV thermal runaway barrier
Technical Specifications
Density
0.002–0.200 g/cm³ (varies by form)
Temperature Resistance
Up to 650°C (silica aerogel); composite grades typically to 200°C+
Sustainability
Sustainability Rating
Aerogel production via supercritical drying is energy-intensive, though ambient pressure drying processes are reducing energy requirements. Silica aerogel is derived from silica (abundant) and is non-toxic. The thermal insulation performance of aerogel can significantly reduce energy consumption in vehicles, particularly for EV battery thermal management. End-of-life aerogel composite recycling is not yet established. The lifecycle energy benefits of improved thermal efficiency are considered to outweigh production energy costs in most automotive applications.