Aerogel Technologies, LLC | Airloy® Products
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Airloy® Products


Airloy Ultramaterials are available in different compositions, densities, and form factors. Different Airloy compositions offer different materials properties such as operating temperature range, flammability properties, water resistance, light transmissiveness, strength and stiffness vs. density, and chemical stability. Related compositions are grouped by series. Each series may contain several different formulations optimized for different applications.

Airloy materials are designated by a formulation number and density class. Airloy materials of different compositions are offered in different density classes to help end users select materials that optimize weight, structural properties (which improve as density increases), thermal conductivity (which decreases as density decreases), and other materials properties for their application.

Density Classes

Materials properties of Airloy Ultramaterials vary with density. Properties such as mechanical strength and stiffness increase with increasing density, while properties such as thermal conductivity tend to decrease with decreasing density. As a result, Airloy Ultramaterials are sold by density class to provide products that optimize materials properties differently.

Density classes are described in the following table.

Density Class Bulk Density Qualitative Description
XL 0.08 g/cc ± 0.02
  • Combine lowest density with high thermal superinsulating properties at decent strength, generally breakable by hand
L 0.10 g/cc ± 0.02
  • Provide the highest thermal superinsulating properties with good strength, generally breakable by hand
M 0.20 g/cc ± 0.05
  • Optimize thermal superinsulation and strength properties, hard to break by hand
MH 0.30 g/cc ± 0.05
  • Optimize thermal insulation and other multifunctional properties with higher strength, hard to break by hand
H 0.40 g/cc ± 0.05
  • Provide high strength and high sound transmission loss properties at a density 3x lighter than plastics, not breakable by hand
XH 0.55 g/cc ± 0.05
  • Maximize strength and sound transmission loss properties while still providing 2x lower density than plastics, not breakable by hand

Not all materials are offered in all density classes due to limitations in the chemistry and feasibility of production of different formulations.

Part Number Format

Airloy materials are denoted by the following part number format:


Part Number Component
Significance Options
A Application
  • A, Aviation
  • C, Construction
  • H, Hydrophobic
  • T, Thermal
  • X, General/Experimental
B Composition series
  • 5, Amorphous Silica/Polyurea Hybrid
  • 6, Amorphous Vanadia/Polyurea Hybrid
  • 10, Polyurea
  • 11, Polyimide
  • 12, Polyamide
  • 13, Polyurethane
  • 14, Polybenzoxazine
  • 4#, Carbon, Derived from Material with Composition Number 1#
C Specific formulation within composition series
  •  1 through 9
D Density class,
see density class table for more information
  • XL
  • L
  • M
  • MH
  • H
  • XH
F Special features
  • Various

Airloy Product Series

Airloy X50 Series

  • Composition: Polymer-crosslinked silica aerogel
  • Target Utility: Light-transmissive applications
  • Features: Transparent materials that are 4x lighter than plastics, more insulating than Styrofoam or still air, and mechanically durable. Look like classic aerogel for an intriguing aesthetic effect and provide insulating properties but provide image-preserving transparent clarity for daylighting applications. Available in 0.3 g/cc with operating temperatures up to 80°C.
  • Available Products: Airloy X56-MH
  • Resources: Materials properties


Airloy X100 Series

  • Composition: Polyurea aerogel
  • Target Utility: Lightweight plastics replacements
  • Features: Excellent mechanical strength and stiffness at low densities. Dramatically superior soundproofing properties over other soundproofing materials over high frequencies. Thermal insulating properties comparable or superior to expanded polystyrene and polyurethane foams. Plastic-like feel, semi-flexible at thicknesses less than 3 mm, easy to machine, thermoformable. Available in 0.1, 0.2, and 0.4 g/cc. Other densities available as custom solutions. Operating temperatures up to 80°C.
  • Available Products: Airloy X103-L, Airloy X103-M, Airloy X103-H, Airloy X103-XH
  • Resources: Materials properties, introduction video, video


Airloy X110 Series


Airloy X130 Series

  • Composition: Polyurethane aerogel
  • Target Utility: Medium-temperature lightweight plastics replacements
  • Features: Excellent mechanical strength and stiffness while still 3-4x lighter than plastics. Dramatically superior soundproofing properties over other soundproofing materials over high frequencies. Thermal insulating properties comparable to expanded polystyrene and polyurethane foams. Easy to machine, thermoformable. Available in 0.3 and 0.4 g/cc. Other densities available as custom solutions. Operating temperatures up to 130°C.
  • Available Products: Airloy X134-MH
  • Resources: Materials properties


Specialty Airloy Formulations

Specialty Airloy formulation classes available as custom solutions include:

  • Airloy X60 Series: Polymer-crosslinked vanadia aerogel, for ballistics applications
  • Airloy X120 Series: Polyamide aerogel, for high-temperature and high-stiffness lightweight plastics replacements that do not trap heat
  • Airloy X140 Series: Polybenzoxazine aerogel, for low-cost high-temperature/high-strength applications
  • Airloy X400 Series: Strong carbon aerogels, for structural electrodes—pyrolyzed versions of aromatic polymer Airloys, for example, Airloy X414 is a high-surface-area electrically-conductive carbonized version of Airloy X114

Materials Properties Ranges by Series

Airloys offer the right optimization of materials properties for your application. Below is a summary of the materials properties spanned by different Airloy series.

For information about specific products in these series, view materials properties for specific Airloy products or view our Airloy product selection guide for more information.

Series Density [g/cc] Young’s Modulus [MPa] Yield Strength [MPa] Thermal Conductivity [W/m-K] Operating Temp [°C]
X50 0.1 – 0.55 1 – 235 0.03 – 6 0.024 – 0.055 130
X60 0.4 – 0.65 220 – 620 5 – 16 0.024 – 0.055 130
X100 0.1 – 0.55 8 – 360 0.4 – 12 0.024 – 0.055 80
X110 0.1 – 0.55 5 – 220 0.2 – 11 0.020 – 0.044 300
X120 0.1 – 0.35 125 – 215 0.6 – 5 0.025 – 0.04 250
X130 0.16 – 0.55 1 – 400 0.04 – 6 0.030 – 0.060 130

Shapes, Sizes, and Form Factors

Airloy Ultramaterials come in a wide variety of shapes, sizes, and form factors to accommodate different applications.

3D parts made from Airloys are typically machined from blanks or molded to specification. A good material for comparison for how shape is imparted onto Airloys is PTFE plastic like Teflon, which is typically either machined by the user or molded to spec by the manufacturer. Some Airloys, particularly Airloy X103, can be thermoformed to impart curvature and other complex features. Airloys are not injection molded or additively manufactured at this time.

Thanks to our patent-pending drying technologies, Airloy Ultramaterials can be produced as 3D shapes, parts, and thin films in arbitrary lengths and widths with practical thicknesses up to 2 cm. Although theoretically parts of any thickness can be produced, thicker parts take longer to produce than thinner parts and so we generally limit part thicknesses to 2 cm maximum. However, thanks to the polymer nature and high-definition pore structure of Airloy Ultramaterials and our company’s patent-pending layered aerogel composites technology, we can produce Airloy parts of arbitrary thicknesses by laminating plates together to make large, machinable 3D blanks.

Current form factors produced by our company and available for purchase on demand through on a product-by-product basis include:

Form Factor
Dimensions Availability
  • 2” x 3” x 0.4”
  • 5 cm x 7.5 cm x 1 cm
On demand through
  • 12” x 12” x 0.4”
  • 30 cm x 30 cm x 1 cm
On demand through
  • 3” x 0.4”
  • 7.5 cm x 1 cm
On demand through
Large panels
  • Up to 40” x 40” x 0.4”
  • 1 m x 1 m x 1 cm
Custom solutions
Very large laminated blanks
  • Arbitrary length, width, and thickness
Custom solutions
Very large non-laminated panels
  • Arbitrary length and width, thicknesses ≤ 1.5 cm/0.6”
Custom solutions
Continuous volume 3D shapes and parts
  • Machined from laminated blankets of arbitrary length, width, and thickness
Custom solutions
 Continuous volume 3D shapes and parts not from laminated blanks
  • Parts that can fit within a cylindrical volume of 6” x 18”
Custom solutions
 Thin films and flexible dust-free blankets
  • Thicknesses of 20 µm to 2.5 mm in arbitrary lengths and widths
Custom solutions
  • Various meshes and particle size distributions for most Airloy materials
Custom solutions

Additional form factors, shapes, and applications integration options for Airloys nay be available through our custom solutions division.