Flexible Aerogel Materials Production Increased, Energy Savings to Follow Published June 23, 2011 By Dr. Gregory Cazzell Materials and Manufacturing WRIGHT-PATTERSON AIR FORCE BASE, Ohio -- Domestic manufacture of high-quality, low-cost aerogel-based blanket material is being expanded, thanks to a DPA Title III program that partners Aspen Aerogels with the Air Force Research Laboratory. Aerogel materials provide thermal and acoustic insulation, infrared signature reduction, and thermal management properties for a variety of ground, air and sea systems. An aerogel is a solid material with nanometer-sized pores, typically made from silica. The pores, which are typically about 10nm in diameter, are formed by the open silica lattice structure. An aerogel offers around 99 percent open porosity, and the nanoscale lattice structure and pores create unique properties in solid material that make it an incredible insulator. As thermal insulation, aerogels are two to five times more effective than foamed plastic or fiberglass. Conventional aerogel materials are brittle and exhibit low shear strength, making them impractical for many applications. However, flexible aerogel materials can be handled and installed like any other thermal insulation. High-volume production will decrease costs to the Department of Defense and ensure a stable and secure domestic supply of these materials. This flexible, high-temperature aerogel materials project, a multi-phased effort between Title III/AFRL and Aspen Aerogels in Northborough, Mass., has completed several significant activities. To date, a high volume production capability has been established and further expansion is under way, manufacturing yields have improved, cycle time has been reduced significantly, and manufacturing costs have decreased. Testing is under way at the National Training Center, Fort Irwin, CA, in the Net Zero plus Joint Capabilities Technology Demonstration. Two prototype aerogel tent-liners are being evaluated. In addition, aerogel material has been investigated for use as a thermal management system in up-armored High Mobility Multipurpose Wheeled Vehicles (Humvees). Ninety thousand square feet of aerogel insulation was recently installed in the interior walls of Wedge 5-2 in the Pentagon during its renovation. It is anticipated that there will be a savings in energy as well as a reduction in CO2 emissions. It is hoped that this small-scale demonstration effort will be a catalyst to migrate the aerogel insulation technology to other Federal installations, thereby accruing significant energy savings.