# Aerogel Manufacturing Breakthroughs Target Net-Zero Housing Retrofits New production processes aim to make ultra-lightweight aerogel insulation commercially viable for older homes. - **Source:** [New Scientist](https://www.newscientist.com/) - **Published:** 2026-10-28 - **Topic:** [Business](https://brifing.si/c/business) - **Original article:** - **On Brifing:** https://brifing.si/s/fb2c26c2-5272-4c2f-b046-1008d988f776 ## The Aerogel Insulation Challenge Aerogels are synthetic, porous solids that trap air to slow heat transfer, offering exceptional insulation and fire resistance. Historically, their high manufacturing costs and energy-intensive production limited usage to aviation and industrial sectors. New startups are now redesigning these processes to unlock potential for residential building retrofits and net-zero goals. ## Addressing Heritage Home Constraints The UK contains approximately 8 million homes with solid walls built before the 1920s. These structures face strict planning regulations that prevent external cladding, while internal insulation often reduces floor space or causes dampness. Aerogel-infused plasters offer a thin, breathable solution that avoids these common structural and spatial trade-offs. ## Thermulon Scaling Production UK-based startup Thermulon has redesigned aerogel production using standardized equipment and cheaper raw materials. Partnering with Best of Lime, they are developing aerogel-infused plaster for historical homes. The company plans to initiate commercial-scale production in Northern Ireland next year, targeting an annual output of 100 tonnes by 2027. ## Keey Aerogel Circular Approach French startup Keey Aerogel utilizes silica waste from the construction industry and continuously recycled solvents to produce aerogels. This method results in a carbon footprint three times smaller than traditional manufacturing. The firm secured 18 million euros in 2025 to build a facility capable of producing 2,000 tonnes annually. ## Diversifying Product Applications Beyond internal plaster, manufacturers are developing diverse applications to improve building efficiency. Keey Aerogel is creating cool roof coatings to block heat entry and formulas for wall cavity insulation. These innovations allow builders to meet tightening standards without reducing room sizes or altering the original footprint of new residential developments. ## Economic and Market Hurdles Despite manufacturing advancements, aerogel products remain more expensive than traditional insulation materials. Experts note that while the technology provides superior thermal performance, startups must overcome significant customer price sensitivity. Success depends on demonstrating long-term value, such as enabling low-carbon heating systems and providing protection against increasingly extreme weather conditions. ## Technical Production Mechanics Aerogels are created by forming a silica nanoparticle gel, which requires a precise supercritical drying process to maintain its porous structure. This stage traditionally consumes significant energy and time. Startups are now optimizing this specific phase to lower costs, making the material viable for mass-market construction and building renovation projects. ## Strategic Path to Net-Zero Retrofitting older homes is essential for national net-zero targets, as these buildings currently consume high volumes of gas for winter heating. Aerogel technology provides a high-performance alternative where conventional methods fail. As production scales in France and the UK, these materials could become a standard component in sustainable building renovation strategies. ## Sources covering this story - https://www.newscientist.com/article/2596016-super-insulating-solid-may-soon-offer-a-net-zero-solution-for-tricky-homes/?utm_campaign=RSS|NSNS&utm_content=home&utm_medium=RSS&utm_source=NSNS — --- _Summary written by Brifing from the original reporting. Copyright in the original article belongs to its publisher; read the full piece at the link above._