Space is an unforgiving environment. Astronauts must be protected from extreme temperatures at both ends of the hot and cold spectrum with materials that perform.
In recent decades, aerogels have emerged as a leading insulation solution for NASA for both spacesuits and spaceships. These materials combine polymers with a solvent to create a gel, then swap the liquid in the gel for air, resulting in the lightest weight, most thermally efficient material on the planet. Originally developed around 1930 by Samuel Kistler, aerogels were first commercialized in the 1950s. Commercial production ceased in the 1970s, but aerogels began their second chapter in the 1990s as NASA set out to create a more easily usable, flexible version of the material than the brittle, costly aerogels previously accessible. Under a long-running contracting relationship with NASA’s Kennedy Space Center, Aspen Systems Inc. made several aerogel advancements including aerogel blankets that innovated hydrocarbon and sub-sea pipe insulation.
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As workable aerogels have become more prevalent, they have gained traction in the apparel and footwear industry. An early brand-side application for aerogel was the Champion Supersuit worn by mountaineer Jamie Clarke for a Mount Everest summit in 2010. The ultrathin gear was 3 millimeters thick, in contrast to the typical 40 millimeters for down coats. After testing the prototype in sub-zero temperatures, Clarke said the suit “did well” and was “warm.” Since then, companies like PrimaLoft and 3M have brought the space-grade aerogel insulation to their customers in numerous forms—including loft and batting insulation infused with aerogel—as part of their broader thermal offerings.
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A newcomer to this space is Solarcore®, Oros Labs’ material technology brand that is unique in that it specializes exclusively in aerogel insulation. Last fall, Solarcore launched its low-density Sc_Foam that is infused with aerogel, achieving the superior insulation properties that aerogel is known for with lower material thickness than competitors. This allows product developers to create gear that keeps wearers warm without adding bulk.
“Warmth is a fundamental need that everybody is trying to solve, and you’re always trying to do it better, more efficiently and with less,” said Jeff Nash, chief technology officer of Oros Labs.
Putting aerogel into a foam overcomes some of the production challenges of the material. Although aerogels are becoming more widely used, earlier iterations on the market required the brittle insulation to be contained in pre-fabricated shapes to avoid breakage and shedding. Solarcore’s patented, proprietary manufacturing process enables Sc_Foam to drop into existing finished goods production workflows, overcoming these previous limitations. For brands and their factory partners, this means an easy swap from conventional insulation such as loft fill and foams. “They don’t have to set up any new special manufacturing to use our product,” said Michael Markesbery, CEO and co-founder of Oros Labs. “It can work seamlessly into footwear, apparel and accessories production.”
Solarcore says the aerogel foam composite is 275 percent more effective than conventional insulation, and its tests have also shown it outperforms its aerogel peers. “The way that we are using aerogel allows us to capture the thermal capabilities of aerogel in a better, more efficient way than a lot of others on the market,” said Markesbery.
Currently, Solarcore foam is being utilized in a variety of footwear and apparel products in the consumer space with brands like Helly Hansen and Merrell. The material firm also has exciting projects with the U.S. military, such as the next generation Arctic Shelter program and the Air Force’s storage solutions for medical supplies.
With its broad applications set and strong thermal capabilities, aerogel is projected to grow at a 13 percent or greater compound annual growth rate to become an over $3 billion market by 2033, according to Future Market Insights. While use in outdoor gear is fairly limited at this point, market growth and awareness should lead to increased usage of this innovative technology.
