THE CHALLENGE
The key challenge in commercializing high-performance porous materials like poly(phenylene sulfide) aerogels lies in the complex, costly, and environmentally taxing manufacturing processes currently required. Traditional methods depend on toxic or high-boiling-point solvents and energy-intensive drying techniques such as supercritical CO₂, making scale-up expensive and inefficient. These processes also limit control over pore structure and mechanical consistency, which are critical for advanced applications in aerospace, automotive, and energy sectors. Additionally, the high melting point and extreme crystallinity of PPS make it difficult to process into lightweight, porous forms or adapt into printable materials for additive manufacturing. This bottleneck restricts the creation of complex, customizable geometries needed for next-generation thermal insulation, filtration, and structural components, presenting both a technical and market-driven gap in scalable, sustainable production methods.
OUR SOLUTION
This innovation enables scalable and environmentally responsible production of high-performance poly(phenylene sulfide) aerogels by using a thermoreversible gelation process with a benign solvent. Poly(phenylene sulfide) is dissolved in 1,3-diphenylacetone at elevated temperatures to form a gel that can be shaped or 3D printed, then safely dried into a lightweight, porous material without the need for toxic solvents or energy-intensive techniques. The resulting aerogels exhibit high strength and stiffness at low densities, with a crystalline fibrillar network that outperforms comparable materials, and remarkable flame-resistant thermal properties. This method combines material performance, design flexibility, and sustainable manufacturing, unlocking new business potential in sectors such as aerospace, automotive, and energy where lightweight, durable, and customizable components are in high demand.
Figure: Overview of the innovation.
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