AeroZero Polymer Aerogel Thermal Barriers and Tapes

Blueshift Materials is a US advanced materials company based in Spencer, Massachusetts that builds on a polymer aerogel technology platform. Its materials are about 85% air, giving thin, light and flexible alternatives to legacy insulation and PTFE laminates for aircraft, spacecraft, batteries, medical devices and electronics.

The AeroZero family includes flame and thermal barriers that combine flame barrier layers with AeroZero insulation and a silicone pressure-sensitive adhesive, protecting composites, metals and PEEK parts from 500°C to 1,200°C. AeroZero low-outgassing tapes protect satellite and spacecraft systems, and PhaseBlue circuit materials offer low-dielectric, PFAS-free laminates for high-frequency PCBs. Customers are engineering teams at spacecraft, aerospace, electric aviation, battery and electronics makers.

• Polymer aerogel platform: nano-porous materials that are about 85% air.
• AeroZero flame and thermal barriers: protection for parts exposed to 500-1,200°C, with silicone PSA backing.
• AeroZero tapes: thin, peel-and-stick, low-outgassing thermal protection for LEO spacecraft.
• PhaseBlue circuit materials: low-dielectric, lightweight laminates for high-frequency PCBs.
• Battery protection: thermal barrier designs for electric aviation and battery packs.
• Easy sampling: sample sheets and rolls orderable online and via the DigiKey Marketplace.

Drone and UAV makers in Vietnam can use AeroZero barriers to protect battery packs and composite parts from heat and fire. Electronics and telecom manufacturers can evaluate PhaseBlue laminates for high-frequency antennas and PCBs. Satellite and space research teams can use AeroZero tapes for lightweight thermal protection of small satellites.

AeroZero flame and thermal barriers withstand direct flame at 1,100°C for up to 30 minutes while wrapping easily over complex shapes. Independent vacuum tests show AeroZero Tapes have 19 times lower thermal conductivity than standard polyimide tape and lower composite temperatures by about 40°C, meeting NASA ASTM E595 outgassing limits. The materials are PFAS-free and halogen-free, supporting US and EU regulatory requirements.

Satellite constellations, electric aviation and high-energy battery packs all need lighter thermal and fire protection, while regulators are restricting PFAS materials such as PTFE. Asia, including Vietnam, is growing as a hub for electronics, drone and battery manufacturing, creating demand for thin aerogel-based thermal materials in export products.

Blueshift Materials, 5 South Spencer Road, Spencer, Massachusetts, USA; co-founded by President Tim Burbey. Won Best Innovation in Commercialization at the inaugural Aviation Week Space Tech Challenge; over 10,000 square feet of AeroZero Tapes deployed in operational spacecraft. Products available on the DigiKey Marketplace.