Outlast Technologies launches innovative Aersulate Wadding

Outlast Technologies has introduced Aersulate Wadding, an advanced fiber-based insulation that combines aerogel technology with sustainable materials to deliver exceptional thermal efficiency in a lightweight form. Building on its NASA-inspired origins, the company continues to lead in developing textile innovations that merge performance, comfort, and environmental responsibility.

At the core of Aersulate is aerogel, known as the world’s lightest solid, made up of nearly 99% air. Outlast has successfully embedded 50% by volume of aerogel directly into viscose fibers, creating insulation that is both ultra-light and highly efficient. It achieves up to 35% higher RCT values in wadding and 37% higher RCT values in needlefelt applications when compared to conventional insulation.

Aersulate Wadding also provides good compression resistance, marking a major step forward in insulation technology. Its aerogel microstructure keeps air locked within a stable, porous framework, maintaining consistent thermal protection even under pressure. It is ideal for technical outerwear, ski apparel, workwear, and footwear, where consistent insulation and long-term performance are essential. It also performs effectively in humid environments.

The wadding combines aerogel made from quartz sand with renewable, wood-based viscose, offering a cruelty-free and eco-friendly alternative to down and synthetic materials. This blend delivers high performance while aligning with ethical and environmental 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 proves that performance and sustainability can coexist seamlessly.”