What is AERSULATE®?

Outlast has succeeded in binding Aerogel, the material with the world’s best insulation values, to the textile using an innovative method. This high-performance material is called AERSULATE^® and exceeds conventional textile insulation in many areas.

How does AERSULATE® work?

What is Aersulate® insulation?

Aersulate® is an advanced textile insulation based on aerogel – one of the lightest and most effective insulating materials known. Integrated into flexible fabrics through a proprietary process, Aersulate® combines ultra-thin construction with exceptional thermal performance.

Originally used in aerospace applications, aerogel offers outstanding insulation due to its extremely high air content and porous structure. Aersulate® makes this high-performance material usable for textiles and technical applications.

How does Aersulate® differ from conventional insulation materials?

Unlike conventional insulation, which relies on bulk and thickness, Aersulate® delivers high performance at minimal thickness.

Effective insulation at just 1–2 mm thickness
Up to 100% higher thermal resistance compared to identical materials without Aersulate®
Performance remains stable under pressure and humidity

Traditional materials often lose insulation when compressed or wet. Aersulate® maintains its structure and performance due to the embedded aerogel network.

Why is Aersulate® so thin yet effective?

The key lies in aerogel’s structure. It consists of a highly porous structure that traps air extremely efficiently - air being the best natural insulator.

Because of this:

High insulation does not depend on thickness
Designers can reduce bulk without sacrificing performance
New product concepts become possible where space is limited

This “space-saving insulation” enables lightweight, slim designs with high thermal protection.

Does Aersulate® work under real-life conditions like pressure or moisture?

Yes. One of the biggest advantages of Aersulate® is its reliable performance in demanding conditions.

Maintains insulation under mechanical pressure
Performs consistently in humid or wet environments
No significant loss of thermal efficiency

This makes it ideal for applications like footwear, workwear, and protective gear where conventional insulation often fails.

Is Aersulate® breathable and water-resistant?

Aersulate® combines insulation with functional comfort properties:

Breathable for improved wear comfort
Water-repellent for reliable performance
Can be combined with flame-retardant properties

This balance makes it suitable for both consumer products and technical applications.

What applications is Aersulate® suitable for?

Aersulate® offers a wide range of applications across industries:

Apparel (including workwear and protective clothing)
Footwear
Bedding and outdoor equipment
Automotive and technical applications
Fire protection and safety gear

Its unique combination of thinness and performance enables solutions where traditional insulation reaches its limits.

Is Aersulate® sustainable?

Aersulate® is based on aerogel derived from quartz – a natural raw material found in sand. It is:

Safe and non-toxic
Produced under high environmental standards
Designed for long-lasting performance

This contributes to more durable and resource-efficient products.

What makes Aersulate® unique?

Aersulate® stands out through a combination of properties rarely found together:

Ultra-thin yet high-performance insulation
Reliable function under pressure and moisture
Lightweight and flexible
Broad application potential

It enables a new generation of products where performance, comfort, and design freedom coexist.

Aersulate® insulation – key benefits at a glance:

Ultra-thin insulation (1–2 mm)
High thermal resistance
Works under pressure and humidity
Lightweight and breathable
Based on aerogel technology
Made in Germany

What is Aersulate® Wadding?

Aersulate® Wadding is a high-performance insulation material in which aerogel is integrated in high amounts (50% by volume). It combines the excellent insulating properties of aerogel with the processability and comfort of traditional wadding materials.

How is Aersulate® Wadding different from conventional wadding?

Unlike conventional wadding, which relies on thickness to trap air, Aersulate® Wadding delivers high insulation performance at significantly reduced thickness.

Less bulk
Lower weight
Higher thermal efficiency

This enables slimmer product designs without compromising warmth.

How thin can Aersulate® Wadding be?

Aersulate® Wadding can achieve effective insulation at much lower thickness compared to traditional waddings. Even at comparable weights, it can significantly outperform standard insulation materials.

Does Aersulate® Wadding lose performance under pressure?

No. Aersulate® Wadding maintains almost its full insulation performance even under compression. This is a key advantage over conventional insulation materials, which typically lose trapped air and therefore insulation when compressed (e.g. in footwear, kneeing or tight garments).

Is Aersulate® Wadding suitable for footwear?

Yes, Aersulate® Wadding is particularly well suited for footwear applications.

Performs under pressure
Provides insulation without bulk
Improves comfort in cold environments

It is ideal for boots, outdoor footwear, and work shoes.

Can Aersulate® Wadding be used in apparel?

Yes. Aersulate® Wadding enables lightweight and slim garment constructions while maintaining high insulation performance.

It is suitable for:

jackets
workwear
protective clothing
outdoor apparel

How does Aersulate® Wadding perform in humid conditions?

Aersulate® Wadding retains its insulation performance even in humid environments.
Unlike traditional insulation materials, it does not rely only on air trapped within the wadding, but also on air enclosed within the aerogel’s porous structure. This helps maintain more consistent insulation performance in real-life conditions.

Is Aersulate® Wadding breathable?

Yes, Aersulate® Wadding can be engineered to provide breathability alongside insulation, supporting overall wear comfort.

What are the key benefits of Aersulate® Wadding?

High insulation at low thickness
Lightweight and flexible
Reliable under pressure and humidity
Suitable for demanding applications
Enables new product designs

What applications is Aersulate® Wadding best suited for?

Aersulate® Wadding is ideal for:

footwear
workwear
outdoor gear
protective clothing
technical applications

It is particularly effective where space is limited but high insulation is required.

AERSULATE® has a material thickness of just 1.3 mm with an RCT value of 0.12.

The AERSULATE^® insulation requires ten times less space than conventional forms of insulation with the same insulation performance. AERSULATE^® may also allow insulation to be provided in applications where there is normally too little space. AERSULATE^® also works under the influence of pressure/moisture and in combination with a fire-resistant carrier material is flame-retardant.

No, the Aerogel responsible for the functionality of AERSULATE^® consists of the smallest particles, which can only be seen under the microscope.

Both the production and processing of the Aerogel required for all AERSULATE^®products takes place in Germany. In this way, we fulfill the highest environmental and social standards and rule out any child labor and social exploitation.

Outlast Technologies GmbH based in Heidenheim, Germany, developed the AERSULATE^® technology. Outlast Technologies GmbH is also known around the world for its textile temperature regulating products.

What lies behind AERSULATE®?
What properties do AERSULATE® products offer?
In what areas can AERSULATE® be used?