Outlast Technologies, a global leader in proactive heat management, has announced a game-changing innovation in textile insulation with the launch of Aersulate®, a revolutionary composite fabric that integrates aerogel into flexible textile systems. With performance proven under compression and moisture, Aersulate® offers an unprecedented combination of ultra-thin structure, lightweight comfort, and thermal insulation—even in the most extreme conditions.
Aersulate marks a major step forward in textile science, achieving what was once deemed nearly impossible: making fragile aerogel—an ultra-light, porous material derived from quartz—viable for flexible, durable fabric applications.
“One of the biggest challenges was simply getting the material to stay where we wanted it,” explained Volker Schuster, Head of R&D at Outlast. “Aerogel is so light it disperses instantly unless it’s immediately bound into a stable structure. We had to engineer a system that kept it intact while maintaining its unique insulation benefits.”
Big Protection, Minimal Thickness
Despite measuring just 1–2 millimeters thick—about the width of a credit card—Aersulate® achieves thermal insulation values that match or exceed conventional bulky insulations. Third-party tests by the Institute for Textile and Fiber Research (per EN ISO 11092) confirm:
- Non-woven without Aersulate (1.1 mm): 0.045 m²K/W
- Identical Non-woven with Aersulate (1.1 mm): 0.08 m²K/W
→ A 78% increase in thermal resistance with no change in thickness.
This performance holds even when the fabric is compressed or exposed to moisture, overcoming the limitations of traditional insulations like felts and waddings, which typically lose performance under such conditions.
“Typical materials leak heat when they get wet. Aersulate maintains internal air structure even when damp, keeping insulation levels high,” Schuster added.
Proven Safety in High-Risk Applications
Aersulate is available in multiple fabric versions—including polyester nonwovens for general textiles and aramid-based options for flame-resistant applications. The aramid variant meets rigorous fire safety requirements, making it ideal for firefighters and industrial safety gear.
Key test results:
- Escape time under extreme heat: Over 2x longer than ISO minimums
- Contact heat resistance: 2.5x longer than standard materials
- Radiant heat delay buffer: +54% beyond ISO threshold
These features make Aersulate a critical advancement in occupational safety, particularly in high-risk environments.
Sustainable and Production-Friendly
Aersulate integrates seamlessly into existing textile processes and can be applied to felts, nonwovens, and technical textile composites. It is robust enough for standard garment and protective gear production despite its delicate aerogel core.
The aerogel is derived from quartz, a naturally abundant material that is non-toxic and environmentally safe. All Aersulate products are proudly developed and manufactured in Germany, ensuring high-quality standards and sustainable sourcing.
Expanding Frontiers: Aersulate Fibers
Beyond flat fabrics, Outlast has also introduced Aersulate-based viscose fibers, designed for use as fillings in jackets, sleeping bags, and bedding. These fibers retain insulation even under pressure, enabling lighter and more efficient products for performance wear and outdoor equipment.
“From outdoor apparel and safety gear to aerospace and industrial use, Aersulate enables thermal insulation where it was never possible before,” concluded Schuster.
With Aersulate, Outlast Technologies is not only rethinking how thermal insulation works—it’s redefining where it can go.
