Polyester Gels and Aerogels

THE CHALLENGE

Polymer aerogels offer a unique combination of ultralow density, high porosity, and very low thermal conductivity, making them highly promising for industrial applications in energy storage, aerospace, filtration, and thermal insulation. Their lightweight and tunable mechanical properties give them an edge over traditional materials in demanding environments. However, current production methods are often complex, costly, and environmentally unfriendly. Processes typically rely on hazardous solvents, toxic crosslinkers, and energy-intensive drying techniques like supercritical CO₂, making large-scale manufacturing difficult and expensive. Small changes in temperature or polymer concentration during production can lead to inconsistent material quality, affecting both performance and reliability. Moreover, limited solvent recovery and residual toxicity raise concerns around recyclability and regulatory compliance. For businesses, this means that despite strong market potential in sectors like construction, aerospace, automotive, and packaging, current fabrication hurdles prevent efficient scale-up and market entry, highlighting the need for greener, more controllable, and cost-effective manufacturing processes.

OUR SOLUTION

We offer a scalable and sustainable method for producing high-performance aerogels from recycled or virgin PET using a single-step thermal process and a benign food-grade-additive solvent. Unlike traditional methods that rely on toxic chemicals or complex multistep procedures, this approach uses safe, recyclable materials and simple heating and cooling to form ultra-light, porous structures with excellent thermal insulation and mechanical strength. The process avoids additives or crosslinkers, minimizes waste, and allows precise control over the aerogel’s structure and properties, making it ideal for energy-efficient applications in construction, packaging, and transportation. With solvent recovery built into the process and compatibility with recycled plastics, this innovation supports circular economy goals while offering businesses a cost-effective path to premium insulation and lightweight materials.

Figure: Lightweight PET aerogel supported upon a delicate dandelion seedhead and PET aerogel Supporting over 300 times its own weight.

Advantages:

• Uses a new benign, FDA-approved food-grade additive solvent (1,3-diphenylacetone)
• Converts recycled PET into high-performance, low-cost aerogels
• Delivers ultra-low thermal conductivity and high mechanical strength
• Enables precise, tunable microstructure with minimal shrinkage

Potential Application:

• Thermal insulation materials
• Lightweight structural composites
• Oil–water separation membranes
• Water filtration membranes