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Technology — What Is Aerogel?

What Is Aerogel?
The Science of Lightweight
Thermal Protection

Aerogel is an ultra-light, nano-porous advanced material — more than 90% air by volume — with one of the lowest thermal conductivities of any known solid. Levron Aerogel applies this remarkable material platform to battery safety, thermal protection, industrial insulation, and advanced engineering systems.

0.012
W/m·K conductivity
>90%
Air by volume
50–100
nm pore size
165°
Superhydrophobic
1300°C
Max capability
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Understanding the Material

Aerogel Is an Ultra-Porous
Solid — Mostly Made of Air

Aerogel is not a foam. Not a fiber. Not a conventional bulk insulation material. It is an advanced engineered solid with a three-dimensional nano-scale network — a material so porous that more than 90% of its volume is trapped air. Despite being one of the lightest solid structures known, it delivers some of the strongest thermal insulation performance available.

An Advanced Engineered Material

Aerogel belongs to a class of ultra-light, high-performance materials created through precise sol-gel chemistry. Levron Aerogel's platform centers on silica aerogel — engineered at the molecular scale for thermal protection.

Silica platform

More Than 90% Air by Volume

The internal structure is overwhelmingly composed of trapped air — confined within billions of nano-scale pores. This creates one of the lightest solid materials ever produced, with densities as low as 3 mg/cm³.

>90% air

Exceptional Thermal Performance

Pure silica aerogel achieves thermal conductivity as low as 0.012–0.016 W/m·K. Levron Aerogel Felt delivers ~0.022–0.024 W/m·K in applied product form — among the lowest of any commercially available insulation material.

0.012 W/m·K

Nano-Porous Architecture

Pore sizes of 50–100 nm — smaller than the mean free path of air molecules. This physically constrains gas-phase heat transfer, creating an insulation mechanism that is fundamentally different from conventional materials.

50–100 nm pores

Not Foam, Not Fiber, Not Bulk

Aerogel is distinct from all conventional insulation categories. Its nano-scale pore network creates properties that foams, fibers, and bulk materials cannot achieve — thinner, lighter, and more thermally efficient.

Unique material class

Multifunctional Material Platform

Beyond thermal insulation: aerogel can be engineered for fire resistance, hydrophobicity, acoustic control, filtration, and chemical absorption — multiple functions within a single material layer.

Multi functional
The Science — Simply Explained

How Does a Material That Is
Mostly Air Block Heat?

Aerogel's thermal performance comes from its nano-porous architecture. Billions of tiny pores trap air at the molecular level, simultaneously suppressing all three mechanisms of heat transfer: conduction, convection, and radiation.

Macro Scale
Solid Aerogel Form
Appears as a translucent, solid material. Incredibly light — can rest on a flower without crushing it.
Micro Scale
Pore Network — 50–100 nm
Billions of nano-pores create an intricate three-dimensional silica network. Porosity: 90–95%.
Nano Scale
Trapped Air Molecules
Air molecules are physically confined — unable to move freely, eliminating convection and limiting conduction.

Three Heat Transfer Mechanisms — All Suppressed

Unlike conventional materials that address one or two heat transfer mechanisms, aerogel's nano-porous structure simultaneously suppresses all three.

🔴
Conduction
✓ Suppressed
The silica network creates tortuous, indirect solid pathways. Heat must follow a long, winding route through minimal solid material — dramatically reducing conductive heat transfer.
🔵
Convection
✓ Eliminated
Pores smaller than 100 nm physically confine air molecules. They cannot circulate or form convective currents — the mechanism simply cannot operate at this scale.
🟡
Radiation
✓ Scattered
Infrared radiation is scattered and absorbed within the vast internal pore network. The enormous surface area (~700 m²/g) provides countless interfaces that disrupt radiative heat flow.
Beyond Conventional Insulation

Why Aerogel Is Fundamentally
Different from Traditional Materials

Conventional insulation works by trapping air in large pockets, requiring thick layers for adequate performance. Aerogel traps air at the molecular level — achieving superior thermal resistance in a fraction of the thickness.

📐
3× Thinner at Equal Performance

Where stone wool needs 6 cm, aerogel achieves the same thermal resistance in ~2 cm. This compactness is not incremental — it is transformative for space-constrained engineering systems.

⚖️
Ultra-Lightweight — >90% Air

Aerogel's >90% air structure means it adds minimal mass to any system. In weight-sensitive applications — EVs, aerospace, portable equipment — this translates directly to better performance and efficiency.

💧
Hydrophobic — Stable When Wet

Conventional insulation absorbs moisture and loses 50%+ of thermal efficiency. Aerogel's 165° superhydrophobic surface rejects water completely — maintaining full performance in all conditions.

🔥
High-Temperature Capable

Standard glass wool fails at 400–500°C. Levron Aerogel operates to 650°C (standard) and 1300°C (ceramic variant) — covering temperature ranges that conventional materials simply cannot address.

🔬
Multifunctional, Not Single-Purpose

Beyond insulation: fire resistance, acoustic control, filtration, hydrophobicity, and chemical stability — multiple engineering functions integrated into a single material layer.

Thickness for Equal Thermal Resistance
Lower is better — achieving the same insulation in less space
Stone Wool 6 cm
6 cm
Glass Wool 5–6 cm
5–6 cm
Standard Aerogel 2–3 cm
2–3 cm
Levron Aerogel ~2 cm
~2 cm
Indicative comparison for equivalent thermal resistance at ambient conditions
Key Material Properties

Nine Extraordinary Properties
One Material Platform

Each property is a direct consequence of aerogel's nano-porous architecture. Together, they create a multifunctional material platform unlike anything in conventional insulation.

🔥
Low Thermal Conductivity
0.012–0.016 W/m·K (platform) · 0.022–0.024 W/m·K (felt)
Among the lowest thermal conductivities of any solid material. Nano-pores suppress conduction, convection, and radiation simultaneously — creating near-minimum heat transfer.
🪶
Ultra-Light Structure
>90% air by volume · One of the lightest solids known
Overwhelmingly composed of trapped air. Density can be as low as 3 mg/cm³ in pure form. Even in reinforced product formats, mass is dramatically lower than conventional insulation.
🕳️
High Porosity
90–95% porous · 50–100 nm pore sizes
Nano-scale pores smaller than the mean free path of air molecules. This structural characteristic is the fundamental reason for aerogel's exceptional thermal performance.
💧
Superhydrophobic Surface
165° contact angle · Active up to 650°C
Complete water rejection — droplets bead and roll off the surface. This hydrophobic behavior persists under mechanical stress and at temperatures up to 650°C, ensuring stable real-world performance.
🌡️
High-Temperature Capability
Standard: -200°C to +650°C · Ceramic: up to 1300°C
Glass wool-reinforced felt operates across the full -200°C to +650°C range. For extreme environments, ceramic wool variants extend the upper limit to 1300°C.
🛡️
Fire Resistance
Published 1000°C flame narrative · A1 non-combustible
In controlled testing, 2cm Levron Aerogel Felt outlasted 9cm of combined conventional materials (5cm stone wool + 4cm glass wool) under 1000°C direct flame exposure.
🔬
Extraordinary Surface Area
~700 m² per gram
Each gram of aerogel contains approximately 700 square meters of internal surface area — enabling exceptional filtration, chemical absorption, and thermal control capabilities.
🌿
Environmental Stability
20+ year lifespan · No degradation · No maintenance
No biological growth, no bacteria, no mold. Chemically inert and UV-resistant. Maintains full thermal performance across decades without any maintenance cycle.
⚙️
Multifunctional Engineering
Thermal + Fire + Acoustic + Filtration + Hydrophobic
A single material layer that addresses multiple engineering requirements simultaneously — reducing component count, system complexity, and total installed weight.
Silica aerogel cross-section revealing nano-porous structure at 50-100nm scale with trapped air network
Material Science Deep Dive

Inside the Nano-Porous
Architecture of Aerogel

The exceptional performance of aerogel is not achieved by adding more material. It is engineered into the fundamental molecular structure — a three-dimensional silica network that transforms the physics of heat transfer.

Silica Aerogel Platform

Levron Aerogel's core platform is built on silica (SiO₂) — one of the most abundant, stable, and well-understood material chemistries. The sol-gel synthesis process creates a continuous three-dimensional silica network with precisely controlled pore architecture.

How >90% Air Functions as a Solid

The silica network forms an incredibly fine scaffold — accounting for only 5–10% of volume — that holds its shape while the remaining 90–95% is trapped air. This architecture creates a material that behaves as a solid but has the density characteristics of a gas.

Surface Chemistry & Hydrophobic Behavior

Surface modification creates superhydrophobic behavior (165° contact angle) that persists to 650°C. This is not a coating — it is chemically bonded to the silica network, ensuring hydrophobicity remains stable under mechanical stress and thermal exposure.

How Structure Controls Performance

Pore size controls convection suppression. Solid-phase fraction controls conduction pathways. Surface area controls radiation scattering. Every performance characteristic traces back to the nano-porous architecture — making aerogel a material where structure is function.

Modern Engineering Relevance

Why Aerogel Matters in
Modern Engineering Systems

Modern systems need lighter, thinner, smarter thermal protection materials. Aerogel's unique combination of properties makes it relevant across the most demanding application environments — from electric vehicle battery packs to industrial furnace walls.

⚡
EV Battery Safety
Why does aerogel matter here?
Cell-to-cell and module-level thermal barriers that contain thermal runaway events. Ultra-thin protection maximizes battery energy density while providing critical safety containment time.
Explore EV Safety →
🔋
Battery Pack Fire Barriers
Why does aerogel matter here?
Fire-resistant barriers between battery modules and adjacent structures. 2cm Levron Felt withstands 1000°C direct flame — providing passive protection without active cooling systems.
Explore Fire Barriers →
🏭
Energy Storage Systems
Why does aerogel matter here?
Large-scale ESS and BESS installations require compact thermal management between cells and modules. Aerogel enables higher energy density in smaller footprints with improved safety margins.
Explore ESS →
🏗️
Industrial Heat Management
Why does aerogel matter here?
Pipe insulation, boiler wrapping, furnace lining — where 3× thinner insulation saves space, reduces weight, and improves process efficiency. Hydrophobicity eliminates moisture-related performance degradation.
Explore Industrial →
❄️
Cryogenic Systems
Why does aerogel matter here?
Operating range extends to -200°C, with superhydrophobic behavior ensuring consistent performance regardless of moisture exposure — a critical advantage over conventional cryogenic insulation.
Learn More →
🛡️
Defense & Special Applications
Why does aerogel matter here?
Lightweight, compact thermal protection for mission-critical systems. Every gram and millimeter saved translates to improved range, payload, and operational flexibility.
Explore Defense →
The Levron Aerogel Product Platform

From Material Science to
Engineered Product Solutions

Levron Aerogel is not only explaining aerogel — we are applying it. Our product platform translates nano-porous material science into commercially ready, engineered product formats for real-world thermal protection challenges.

📋
Levron Aerogel Felt
Flexible thermal barrier sheet — silica aerogel reinforced with glass or ceramic wool. The core product format for flat, wrapped, and layered thermal protection.
Explore Felt →
⬡
Levron Aerogel Granules
Precision silica aerogel particles for cavity fill, composite integration, and specialized applications requiring volumetric thermal protection.
Explore Granules →
🧱
Thermal Barrier Sheets
Engineered multi-layer thermal barriers for battery packs and module-level fire protection — precision die-cut for specific geometric requirements.
Explore Sheets →
🔧
Custom Solutions
Application-specific configurations co-developed with OEMs and system integrators. Custom thickness, reinforcement, composite structures, and form factors.
Start Discussion →

EV Battery Safety Solutions

Cell-to-cell barriers, module-level fire barriers, and integrated thermal management for electric vehicle battery packs.

Battery safety

ESS / BESS Solutions

Thermal protection for large-format energy storage systems — containerized, rack-mounted, and modular configurations.

Energy storage

Defense & Special Applications

Mission-critical thermal protection for defense programs, special engineering projects, and confidential co-development partnerships.

Mission critical
Material Comparison

Aerogel vs. Conventional
Insulation Materials

A structured evaluation across key performance parameters. This comparison illustrates why aerogel represents a different class of thermal protection — not just an incremental improvement.

Property Stone Wool Glass Wool Standard Aerogel Levron Aerogel
Thermal Conductivity 0.035–0.045 W/m·K 0.032–0.044 W/m·K 0.018–0.025 W/m·K 0.012–0.016 W/m·K
Max Temperature 500–700°C 400–500°C 600–900°C Up to 1300°C
Water Resistance Poor — absorbs moisture Poor — loses efficiency Moderate 165° superhydrophobic
Fire Test (1000°C) 5cm fails at 9 min 4cm fails at 9 min Variable 2cm — test stopped
Thickness for Equal R 6 cm 5–6 cm 2–3 cm ~2 cm
Weight / Density High (40–200 kg/m³) Moderate (10–96 kg/m³) Low Ultra-light (>90% air)
Multifunctionality Insulation only Insulation only Insulation + some Thermal + Fire + Hydro + Acoustic
Expected Lifetime 10–15 years 10–15 years 15–20 years 20+ years

Values represent Levron Aerogel internal testing data compared to representative ranges for conventional material classes. Actual performance depends on specific configurations and operating conditions.

Property Performance Profile
Levron Aerogel
Conventional Insulation
Thermal Conductivity Comparison
Lower thermal conductivity = better insulation performance
Stone Wool 0.035–0.045 W/m·K
0.045
Glass Wool 0.032–0.044 W/m·K
0.044
Standard Aerogel 0.018–0.025 W/m·K
0.025
Levron Aerogel 0.012–0.016 W/m·K
0.012
Platform-level thermal conductivity values at ambient temperature
Performance Under Real Conditions

Fire Resistance, Moisture Stability,
and Long-Term Resilience

A material's laboratory performance means nothing if it cannot maintain that performance in real-world conditions. Aerogel's resilience against fire, moisture, and environmental degradation is what makes it more than a laboratory curiosity.

🔥
1000°C Flame Resistance
2 cm Levron > 9 cm conventional
In controlled 1000°C flame testing: 5cm stone wool + 4cm glass wool (9cm total) failed within 9 minutes. A single 2cm Levron Aerogel Felt layer survived continuous exposure — the test was stopped voluntarily with the material still intact.
💧
Superhydrophobicity
165° contact angle · Active to 650°C
Water contact angle of 165° — among the highest of any engineering material. Conventional insulation loses 50%+ efficiency when wet. Levron maintains identical performance in dry, humid, wet, or salt-spray environments.
⏳
Long-Term Stability
20+ year expected lifespan · Zero maintenance
No performance degradation over time. No biological growth. No bacteria or mold. Chemically inert and UV-resistant. The material delivers the same protection on day one and year twenty.
Why Moisture Stability Matters

Most conventional insulation materials absorb moisture over time — especially in outdoor, underground, or humid industrial environments. When insulation absorbs water, its thermal conductivity increases dramatically, often losing half or more of its insulating effect. Aerogel's superhydrophobic surface eliminates this failure mode entirely.

Why Fire Resistance Matters

Thermal protection materials must not become part of the problem during a fire event. Aerogel's A1 non-combustible classification means it does not contribute to fire load, cannot sustain flame, and maintains structural integrity under extreme thermal exposure — the shielding itself never becomes a vulnerability.

Why Levron Aerogel

A Serious Applied-Materials
Company, Not a Lab Project

7 years of dedicated R&D. 14,000 m² integrated production. An existing product platform. Levron Aerogel is a real advanced materials company — established, scalable, and partnership-ready.

01

7 Years of Focused R&D

Thousands of laboratory experiments spanning silica, polymer, metal oxide, carbon, and cellulose aerogel systems. Deep chemistry knowledge enabling rapid material customization for specialized requirements.

02

14,000 m² Integrated Facility

Complete vertical integration — from raw material processing through Sol-Gel synthesis to final product formation. Full quality control at every production stage. Not dependent on external supply chains.

03

Existing Product Platform

Commercial products already in market — aerogel felt, granules, and thermal barrier sheets. This is not a technology in development; it is a technology in production and application.

04

Advanced Chemistry Development

Beyond silica: R&D capabilities across polymer aerogel, metal oxide aerogel, carbon aerogel, and cellulose aerogel — enabling next-generation materials for emerging engineering challenges.

7 Years
Dedicated R&D
14,000 m²
Integrated Facility
5+
Aerogel Chemistries
Custom
Co-Development Ready
Global
Partnership Platform
Knowledge Center

Technical Resources &
Educational Materials

Access technical documentation, educational explainers, and downloadable resources to support your aerogel material evaluation and understanding.

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Levron Aerogel Felt — Technical Datasheet

Full specifications: thermal conductivity, temperature range, fire classification, dimensional options, and environmental performance data.

Download PDF →
📄
Levron Aerogel Granules — Technical Datasheet

Particle size, thermal conductivity, surface area, hydrophobicity, and application guidance for granule-based configurations.

Download PDF →
🔬
Material Safety Data Sheet (MSDS)

Environmental and safety specifications. Non-toxic, eco-safe material compliant with workplace safety requirements.

Download MSDS →
📊
Thermal Conductivity Explainer

Understanding what makes aerogel's 0.012 W/m·K thermal conductivity exceptional — and what it means for your application requirements.

Request Guide →
💧
Hydrophobicity Explainer

Why 165° contact angle superhydrophobicity matters for insulation reliability — and how it maintains thermal performance in wet environments.

Request Guide →
📦
Request Material Sample Kit

Receive physical samples of Levron Aerogel Felt and Granules for hands-on evaluation and internal testing protocols.

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Aerogel Engineering FAQ

What exactly is aerogel made from?

The core aerogel platform is built on silica (silicon dioxide, SiO₂) — one of the most abundant materials on Earth. Through a sol-gel synthesis process, silica precursors are transformed into a three-dimensional nano-porous network. The liquid within the gel is then replaced with air through careful drying (often supercritical drying), leaving behind the solid silica skeleton surrounding billions of nano-scale air pockets.

How can a material that is 90% air be strong enough to use?

While aerogel has very low density, the interconnected silica network provides sufficient structural integrity for insulation and thermal barrier applications. In product formats like Levron Aerogel Felt, the silica aerogel is reinforced with glass wool or ceramic wool fibers — creating a material that is flexible, mechanically stable, and suitable for engineering applications with compressive strength around 40 kPa.

What is the difference between "platform" and "product" thermal conductivity?

The platform-level thermal conductivity of pure silica aerogel is 0.012–0.016 W/m·K. When aerogel is formed into applied products like felt (with reinforcement fibers), the thermal conductivity is slightly higher — approximately 0.022–0.024 W/m·K — due to the presence of the reinforcement material. Both values are dramatically lower than conventional insulation materials.

Is aerogel safe to handle?

Levron Aerogel products are non-toxic, eco-safe, and human-friendly. They do not produce hazardous dust or fibers under normal handling conditions. Material Safety Data Sheets (MSDS) are available for all products, confirming compliance with workplace safety standards.

How does aerogel compare to polyurethane foam insulation?

Polyurethane foam typically has thermal conductivity of 0.022–0.028 W/m·K — similar to aerogel felt in thermal performance. However, foam lacks aerogel's hydrophobicity (foams absorb moisture), high-temperature capability (foams degrade at relatively low temperatures), fire resistance (foams are combustible), and multifunctional properties. Aerogel provides a fundamentally different performance profile.

Can Levron Aerogel be customized for specific applications?

Yes. Levron Aerogel offers custom configurations including specific thicknesses, reinforcement types (glass or ceramic wool), die-cut geometries, composite laminates, and specialized surface treatments. Our engineering team supports co-development partnerships for application-specific material solutions.

What is the cost of aerogel compared to conventional insulation?

Aerogel has a higher per-unit cost than conventional insulation materials. However, total installed cost analysis often favors aerogel when considering: dramatically reduced material volume (3× thinner), reduced installation labor, lower structural requirements (lighter), longer lifespan (20+ years vs 10–15), zero-maintenance, and elimination of moisture-related performance degradation.

Aerogel Glossary

TermDefinition
AerogelAn ultra-light, nano-porous solid material derived from gel in which the liquid component has been replaced with air, maintaining the solid structure.
Sol-Gel ProcessA chemical synthesis method used to create solid materials from small molecules. In aerogel production, it transforms precursor solutions into a gel network.
Nano-PorousHaving pores on the nanometer scale (1–100 nm). Aerogel pores are typically 50–100 nm in diameter.
Thermal ConductivityA measure of a material's ability to conduct heat. Lower values = better insulation. Measured in watts per meter-kelvin (W/m·K).
SuperhydrophobicHaving extremely high water repellency, defined by water contact angles exceeding 150°. Levron Aerogel achieves 165°.
PorosityThe percentage of a material's total volume that is void (air-filled). Aerogel porosity: 90–95%.
Mean Free PathThe average distance a molecule travels before colliding with another. When pore size < mean free path, gas-phase heat transfer is suppressed.
Thermal RunawayAn uncontrolled chain reaction in battery cells where rising temperature triggers further heat generation, potentially leading to fire or explosion.
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EV Battery Safety

Learn how aerogel thermal barriers protect battery packs from thermal runaway propagation.

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Thermal Barrier Sheets

Precision-engineered thermal barriers for battery packs and module-level fire protection.

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Discuss your application requirements with our materials engineering team.

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