Outlast Technologies has unveiled Aersulate Wadding, an advanced fibre-based insulation that combines aerogel technology with sustainable materials to achieve high thermal efficiency at an exceptionally low volume. Drawing on its NASA-inspired heritage, the company continues to pioneer textile innovations that balance performance, comfort, and environmental responsibility.

At the heart of Aersulate is aerogel, recognised as the world’s lightest solid and composed of up to 99% air. Outlast has embedded an impressive 50% by volume of this material directly into viscose fibres, producing an insulation that is both ultra-light and highly effective. Independent laboratory tests have confirmed up to 35% higher RCT values in wadding and 37% higher RCT in needlefelt applications, compared to conventional insulation materials. The same warmth can be achieved with up to 35% less volume, offering significant advantages for designers and manufacturers seeking performance without bulk.

Aersulate Wadding’s exceptional compression resistance marks a major advancement in insulation technology. Conventional materials typically lose efficiency when compressed, as trapped air — the main insulating medium - escapes under pressure. Aersulate’s aerogel-rich microstructure, however, retains air within a stable, porous framework that resists compression. The result is consistent thermal protection even when the material is compacted, maintaining warmth during activities such as sitting, bending, or kneeling.

This durability under pressure makes the material particularly suitable for applications in technical outerwear, ski apparel, protective workwear, and even footwear, where flexibility and long-term performance are critical. The insulation also performs reliably in humid environments, where other materials often lose thermal efficiency.

Sustainability lies at the core of the Aersulate innovation. The wadding combines aerogel derived from quartz sand with renewable, wood-based viscose, creating an animal-free, environmentally conscious alternative to down and conventional synthetics. This blend ensures high performance without compromising ethical or ecological standards.

“With our patent-pending fibre technology, Aersulate redefines what textile insulation can be: thin, light, and powerful,” said Ari Pachur, Senior Business Development Manager Overseas at Outlast Technologies. “This innovation shows how performance and sustainability can go hand in hand.”

The launch of Aersulate Wadding strengthens Outlast’s position as a leading developer of high-performance temperature-management materials for apparel, bedding, and footwear. Founded on NASA research originally developed to regulate astronauts’ body temperatures, Outlast continues to deliver advanced textile solutions for comfort and performance to leading global brands.

Outlast Technologies’ Aersulate Wadding video…

www.outlast.com