Application Case Studies

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In the landscape of advanced materials, theoretical data is merely the starting point. At AIMRSE, we believe true reliability is forged in the crucible of real-world application. Our case studies are more than successful projects—they are empirical evidence of our insulation materials' superior performance.

Real-World Success: How Our Thermal Solutions Perform Under Extreme Conditions

EV Battery
Thermal Runaway

Electric Vehicle Manufacturing

Certified Safe
Challenge — A leading automotive brand was developing a new generation of high-energy-density battery packs. Their primary concern was preventing thermal propagation in the event of a cell failure. They needed a material that could withstand extreme heat from a single cell while keeping neighboring cells below critical temperatures, all within a very tight space and without adding significant weight.

"We evaluated numerous solutions, but only AIMRSE's aerogel products consistently provided the thermal barrier we needed. The material's behavior under abuse testing gave us the confidence to move forward."
— Lead Battery Safety Engineer

Solution & validation — Our team collaborated closely with the manufacturer's engineers to integrate Aerogel Thermal Pads between each cell. The pads, only a few millimeters thick, combined extremely low thermal conductivity with high compressibility to accommodate cell swelling. Extensive testing—including nail penetration, overcharge, and thermal stability—demonstrated that even when one cell entered thermal runaway, the pads prevented any propagation to adjacent cells. The solution also passed stringent fire safety standards and maintained performance after aging simulations.
Outcome — The battery is now incorporated into multiple vehicle models, providing passengers with enhanced safety. The manufacturer has since specified our Aerogel Thermal Pads for future vehicle models, citing not only performance but also the depth of engineering support we provided throughout the development process.
Aerogel Thermal Pad
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Kiln Energy
Saving

Specialty Chemicals Producer

15% Fuel Reduction
Challenge — A chemical plant operated a large tunnel kiln for calcining materials at very high temperatures. The original refractory lining was heavy, had high heat storage, and allowed significant heat loss through the shell, leading to high energy costs and uncomfortable working conditions near the kiln. The company aimed to reduce fuel consumption and improve temperature uniformity without a complete kiln rebuild.

"We were skeptical at first about replacing dense refractory with fiber, but AIMRSE provided detailed thermal modeling and references from similar retrofits. The actual results exceeded our expectations."
— Plant Operations Director

Solution & Implementation — After analyzing the kiln's thermal profile, we proposed a two-layer lining: a hot face of high-strength polycrystalline alumina fiber modules capable of withstanding the process temperature, backed by a ceramic fiber blanket for additional insulation. The lightweight construction reduced heat storage dramatically, allowing faster heating and cooling cycles. Installation was completed during a scheduled maintenance shutdown with minimal disruption.
Outcome — After commissioning, fuel consumption dropped by 15%, and shell temperatures decreased dramatically, improving both energy efficiency and worker safety. The kiln achieved more uniform temperature profiles, leading to higher product consistency. Encouraged by the results, the client has since retrofitted two more kilns with our materials and now considers our products as their standard for new builds.
Polycrystalline Alumina Fiber
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Deep Sea
Exploration

Subsea Engineering & Robotics Firm

Protected Electronics
Challenge — A company specializing in deep‑water robotics and instrumentation was developing a new autonomous lander for commercial survey and research operations in the hadal zone, where pressures exceed 110 MPa and water temperature hovers just above freezing. The lander's electronics—batteries, data loggers, and sensors—had to be kept warm and dry. Traditional insulation materials would either collapse under pressure or become thermally conductive. In addition, the housing needed positive buoyancy to return to the surface after each mission, a critical requirement for asset recovery.

"The combination of thermal insulation and buoyancy in one material was exactly what we needed. AIMRSE's syntactic foam based on hollow glass microspheres performs perfectly under pressure."
— Chief Engineer, Subsea Systems

Solution & Testing — We recommended our syntactic foam, manufactured from hollow glass microspheres embedded in an epoxy matrix. It offers low thermal conductivity and low density while withstanding extreme hydrostatic pressure. Before the final build, we pressure‑tested sample blocks in a hyperbaric chamber to the equivalent of full ocean depth; they showed no measurable water uptake or dimensional change. The client's engineers then machined the foam into custom segments that lined the inside of the titanium pressure sphere, encapsulating the battery and electronics.
Outcome — The lander completed multiple dives to the hadal zone, each time returning with pristine data. Internal temperatures remained well above the freezing point of seawater, ensuring reliable electronics performance. The foam also provided the necessary buoyancy for ascent. Based on this success, the company has adopted our syntactic foam for a new fleet of deep‑ocean vehicles.
Syntactic Foams
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Further Proof Across Industries

AlN Substrate Thermal Spread

Semiconductor

AlN Substrate Thermal Spread

A leading chipmaker needed to improve heat dissipation in high-power RF amplifiers. Our high-purity aluminum nitride substrates, with their exceptional thermal conductivity, were integrated into the package. Junction temperatures dropped significantly, enabling higher output power and extended device lifetime. The solution is now used in several generations of their products.

VIP Vaccine Transportation

Cold Chain

VIP Vaccine Transportation

A global logistics provider required a passive container capable of maintaining ultra-cold temperatures for international vaccine shipments. Our Vacuum Insulation Panels, with their extremely low thermal conductivity, were incorporated into the shipper design. In real‑world trials, the container maintained the required temperature for an extended period, even in hot ambient conditions, ensuring vaccine efficacy.

Re-Entry Battery Shieldg

Aerospace

Re-Entry Battery Shield

For a experimental re-entry vehicle, protecting a lithium-ion battery from extreme aerodynamic heating was critical. A custom-shaped aerogel blanket, just centimeters thick, was placed around the battery compartment. During the mission, external temperatures soared, but the battery remained well within its safe operating range, enabling successful data transmission throughout the descent.

High-Temperature Furnace Upgrade

Laboratory

High-Temperature Furnace Upgrade

A materials research lab was struggling with slow heating rates and high exterior temperatures on their tube furnace. By replacing the old insulation with our polycrystalline alumina fiber, they achieved faster ramp rates, improved temperature uniformity, and a cooler outer shell. The upgrade allowed them to conduct more experiments per day and improved safety for researchers.

Every case is backed by full documentation — from initial material characterization to post-installation analysis. We work alongside your engineers to ensure success, just as we have for hundreds of clients worldwide.

Technical data represent typical values. As applications vary, we recommend consulting our technical team to ensure the best fit for your specific requirements.

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AIMRSE - AeroTherm Advanced Insulation Logo

AIMRSE is a global technology leader committed to engineering excellence. As its specialized division, AeroTherm Advanced Insulation provides premier thermal management solutions spanning from -200°C to 1600°C+. We empower the EV, aerospace, and industrial sectors with high-performance aerogels, ceramics, and innovative insulation systems that ensure safety and energy efficiency in the most extreme environments.

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