Aerogels 2025-2035: Technology, Market, Forecasts

Ultralight advanced nanoporous materials, including polymer, silica and composite monoliths, particles, blankets and other forms for EV fire protection, thermal insulation in oil & gas, energy, industrial, aerospace applications and more.

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Aerogels have gained significant attention as fire protection material for electric vehicles (EVs) with the aerogels market for EV batteries growing nearly 20-fold between 2021 to 2024. Due to their exceptionally low thermal conductivity, low density, hydrophobicity, fire retardancy, and acoustic insulation, aerogels have historically seen steady growth across LNG, industry, energy infrastructure, and several other markets. More recently, polymer aerogels have started to emerge for ultra-lightweight applications that require mechanical durability, across aerospace and aircraft (e.g. eVTOL), apparel, radio-frequency applications, and more. IDTechEx evaluated all of these markets and forecasts the overall aerogels market to grow at a CAGR of 12.2% from 2025 to 2035.
 
IDTechEx's report on the aerogels market offers a comprehensive and independent analysis of the global aerogel market giving detailed ten-year market forecasts segmented by application and material type. The materials covered include polymer, silica, and silica composite blankets, pads, sheets, foams, and a range of other form factors. The report also benchmarks commercially available aerogels across several applications, including thermal barriers for EV batteries, oil & gas, building & construction, and more. Assessment of aerogel applications is also included for other markets such as energy storage, electronic appliances, daylighting & windows, and many more.
 
IDTechEx has been studying the aerogel industry for many years with technical experts conducting an extensive number of primary interviews to bring the reader a granular and detailed assessment of this industry.
 
aerogels market, aerogels forecast, aerogel applications, aerogel players, aerogel trends, ev battery, fire protection materials
 
Aerogels are ultralight materials with extremely low thermal conductivity. IDTechEx benchmarked over 130 aerogel products in the market across different material types and form factors such as blankets, foams, particles, panels, and more. Source: IDTechEx
 
EV Batteries Will Be the Dominant Application for Aerogels in The Future
Historically, aerogels have experienced steady market growth with progress being somewhat slower than some would expect, though this has largely been due to competition with lower-cost incumbent insulation materials. However, since 2020, the emergence of aerogels as fire protection material for electric vehicle (EV) batteries has provided a new and rapidly growing opportunity for the aerogel market.
 
As standards evolve and the EV market continues to grow there will be an increased focus on thermal runaway propagation prevention, fire protection, and providing longer escape times for vehicle passengers. IDTechEx predicts that this will be the dominant application for aerogels within the forecast period, with significant adoption in China by players such as BYD and CATL, but also globally with adoption from GM, Toyota, and Audi to name a few. The report provides benchmarking of aerogels against other fire protection materials for EV batteries and an analysis of players and partnerships.
 
Chinese Manufacturers Driving Expansion in Global Production Capacity
IDTechEx has been monitoring the growth of both global and regional aerogel manufacturing capacity since 2015. China has become increasingly dominant in this sector, with numerous players rapidly ramping up production over the past few years. According to IDTechEx estimates, China currently accounts for approximately 97% of the global production capacity, with several major expansions planned.
The report includes a comprehensive assessment of key aerogel manufacturers such as Aspen Aerogels, Cabot, IBIH, Nano Tech, Armacell, LG Chem, and several others, covering their capacity, products, production processes, planned expansions, and more. Additionally, it features an extensive patent analysis, highlighting key assignees, applications, and targeted regions.
 
Historically, the high cost of aerogels compared to incumbent insulation materials has hindered their widespread growth. IDTechEx's report delves into how the industry is addressing the challenge to lower manufacturing costs through process innovations, and alternative manufacturing methods.Coverage and analysis of manufacturing processes and drying technologies such as supercritical drying, ambient pressure drying, and freeze drying are included, with advances from start-up companies, and relevant academic or industrial research. There also remains a constant interest in new materials, utilizing sustainable or recycled feedstocks, and ambitious manufacturing techniques such as 3D printing. Overall, IDTechEx forecasts the aerogels market to grow 3.2-fold at a CAGR of 12.2% from 2025-2035.
 
Key aspects
Benchmarking of aerogel products:
  • Thermal conductivity
  • Density
  • Applications and maturity
 
Analysis of aerogel applications:
Electric vehicle batteries, oil and gas, industrial, building and construction, windows, apparel, transportation, energy storage, aerospace, and several others
 
10 year market forecasts in US$:
  • Aerogel type: silica, carbon and polymer aerogels
  • Aerogel applications: EV Battery, industrial, LNG & energy, and others
  • Aerogels as fire protection in EV battery packs: EV, eVTOL/eCTOL
 
10 year market forecasts in kg:
Aerogels as fire protection in EV battery packs: kg
Report MetricsDetails
Historic Data2021 - 2024
CAGRThe Global Aerogel Market to grow at a CAGR of 12.2%
Forecast Period2025 - 2035
Forecast UnitsUS$
Regions CoveredWorldwide, China
Segments CoveredEV Battery (incl. eCTOL/eVTOL) Industrial (incl refineries) LNG and Energy Infrastructure Building and Construction Apparel, Footwear and Sport Aerospace Electronics Window Other
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1.EXECUTIVE SUMMARY
1.1.Aerogels are ultralight materials with high porosity, surface area, and low density
1.2.Aerogel Thermal Conductivity and Density Benchmarking Study 2025
1.3.Aerogel Forecast 2021-2035: Polymer and Silica-Based Aerogels
1.4.Aerogel Manufacturing Process by Player
1.5.Overview of aerogel manufacturer production capacity and process
1.6.Current capacity and planned expansions of key aerogel manufacturers
1.7.Trend in regional manufacturing capacity: China increasingly dominates
1.8.Growth in Global Aerogel Manufacturing Capacity 2015-2025
1.9.China Dominates Aerogel Manufacturing but Less So for Revenue (2025)
1.10.Aerogels span a wide range of applications
1.11.Silica and Silica Composite Aerogel Forecasts 2021-2025: Applications/Sector
1.12.Fire Protection Materials in EV Batteries and the Role of Aerogels
1.13.Growing EV Market, regulations, and the opportunity for thermal barriers
1.14.Fire Protection Materials: Main Categories
1.15.Benchmark: Aerogels vs Other Fire Protection Materials
1.16.Density vs Thermal Conductivity -Thermally Insulating Fire Protection for EVs
1.17.Comparison of Aerogel Fire Protection Materials for EV Batteries
1.18.Forecast: Aerogel Fire Protection Materials for EV, eVTOL, and eCTOL
1.19.Access More With an IDTechEx Subscription
2.INTRODUCTION
2.1.Overview
2.1.1.Aerogels are ultralight materials with high porosity, surface area, and low density
2.1.2.How are aerogels made?
2.1.3.A brief history of aerogels
2.2.Aerogel Types
2.2.1.Aerogel tree by type
2.2.2.IDTechEx evaluated the types of 130 aerogel products in the market
2.2.3.Silica is the most commonly employed aerogel material
2.2.4.Silica aerogel properties by pure form
2.2.5.Key additional properties of silica aerogels
2.2.6.Polymer aerogels are rapidly emerging as a commercial product
2.2.7.Electrically conductive carbon aerogels attractive for energy storage applications
2.3.Aerogel Forms
2.3.1.Aerogels are manufactured in a range of form factors
2.3.2.Distribution of aerogel form factors in the market
2.3.3.Aerogel Particles: Powder aerogel SWOT analysis
2.3.4.Aerogel Particles: Granule aerogel SWOT analysis
2.4.Benchmarking
2.4.1.IDTechEx analyzed properties of 130 aerogel products in the market
2.4.2.Aerogel Thermal Conductivity and Density Benchmarking Study 2025
2.5.Key Applications
2.5.1.Aerogels span a wide range of applications
3.MANUFACTURING METHODS AND PROCESSES
3.1.Overview
3.1.1.Aerogel Manufacturing Process by Player
3.1.2.Scaling of supercritical aerogel manufacturing processes
3.2.Supercritical Drying
3.2.1.Supercritical drying process: overview
3.2.2.Supercritical drying process: closed loop
3.2.3.Supercritical drying process: autoclave loading
3.2.4.Aspen Aerogel's manufacturing of silica composite aerogel blankets
3.2.5.Silica composite aerogels - composites formed from powders and granules
3.2.6.Aspen Aerogel's manufacturing process: patent infringements
3.3.Ambient Pressure Drying
3.3.1.Ambient pressure drying process pioneered by Cabot Corporation
3.3.2.Silica aerogel powder manufacturing processes using ambient drying
3.3.3.Westwood Aerogel's ambient drying processes to manufacture aerogels
3.3.4.Enersens uses ambient pressure drying to manufacture aerogel products
3.3.5.Aerogel Technologies scaling up manufacturing process for polymer aerogels
3.3.6.Monoliths prepared from methyltrimethoxysilane (MTMS) by Tiem Factory
3.3.7.Cost optimised ambient pressure drying process - university research
3.4.Other Methods and Processes
3.4.1.Polymer aerogels can be pyrolyzed to form carbon aerogels
3.4.2.Rapid supercritical extraction
3.4.3.3D printing of aerogels
3.4.4.Alternative monolithic aerogel manufacturing processes - university research
3.5.Sustainable Feedstocks
3.5.1.Research efforts to produce aerogels from sustainable or waste sources
3.5.2.Silica aerogels manufactured using raw silica from waste sources
3.5.3.Aerofybers Technologies focusing on cellulose-based biopolymer aerogels
3.5.4.Aerogel-it developing a range of bioaerogels for thermal solutions
3.5.5.Aerogels from waste cotton fabric material and other feedstocks
3.6.Cost Analysis
3.6.1.Materials and process costs, and process safety can be key limitations
3.6.2.Silica composite aerogels - cost analysis
3.6.3.Ongoing efforts to tackle the high cost of supercritical drying
3.6.4.Cost progression for powder and granule silica aerogels
3.7.Production Capacity and Outlook
3.7.1.Overview of aerogel manufacturer production capacity and process
3.7.2.Current capacity and planned expansions of key aerogel manufacturers
3.7.3.Upcoming notable capacity expansions
4.PRODUCT LANDSCAPE AND PLAYER OVERVIEW
4.1.Player Overview
4.1.1.Market entry of aerogel manufacturers and geographical distribution
4.1.2.Trend in regional manufacturing capacity: China increasingly dominates
4.1.3.Growth in Global Aerogel Manufacturing Capacity 2015-2025
4.1.4.China Dominates Aerogel Manufacturing but Less So for Revenue (2025)
4.1.5.Key Player: Aspen Aerogels targets Energy Industrial and EV markets
4.1.6.Key Player: Cabot Corporation idled aerogel production plant in 2024
4.1.7.Armacell acquires joint venture from JIOS, with JIOS focusing on EV market
4.1.8.LG Chem started commercial production in 2024, targeting EV and Industrial
4.1.9.Svenska Aerogels has several ongoing pilot projects with customers
4.1.10.IBIH Advanced Materials expanding capacity for the transportation industry
4.1.11.Other key Chinese manufacturers and market leaders - status and outlook
4.2.Silica Aerogels
4.2.1.Silica aerogels overview: players, industry and key applications
4.2.2.Properties: Silica aerogel pad/panels and monoliths
4.2.3.Examples of silica aerogels products available in the market
4.3.Silica Composite Aerogels
4.3.1.Aspen Aerogels manufactures composite blankets for Energy, Industrial, and EV
4.3.2.Armacell's ArmaGel range for energy, industrial, commercial, and transport
4.3.3.Silica composite aerogels from key Chinese manufacturers
4.3.4.Examples of silica composite aerogels available in the market
4.3.5.Silica composite aerogels formed from powder and granules - players and progress
4.4.Organic Aerogels
4.4.1.Organic aerogels in the market based on polymers, biopolymers and carbon
4.4.2.Polyimide and polyurea polymer aerogels developed by Aerogel Technologies
4.4.3.Other polymer aerogel products manufactured by Aerogel Technologies
4.4.4.Blueshift materials manufactures polyimide aerogel thin films
4.4.5.Blueshifts AeroZero products: properties
4.4.6.Key carbon aerogel manufacturers - first movers in China to upscale capacity
4.4.7.Graphene and graphite aerogel - Aerogel Core Ltd
5.PATENT ANALYSIS
5.1.Trends in aerogel patent applications and patents issued 2000-2025
5.2.Top patent assignees and the associated geographic distribution
5.3.Patent applications by country and targeted geographic markets
5.4.Notable patent infringement cases: Aspen vs Nano Tech and Alison Hi-Tech
6.APPLICATIONS: FIRE PROTECTION MATERIALS IN EV
6.1.Thermal Runaway and Fires in EVs
6.2.Fire Protection Materials in EV Batteries and Aerogels
6.3.Battery Fires and Related Recalls (automotive)
6.4.Growing EV Market
6.5.Regulations
6.6.Fire Protection Materials: Main Categories
6.7.Fire Protection Materials Comparison
6.8.Density vs Thermal Conductivity -Thermally Insulating Fire Protection for EVs
6.9.Material Intensity (kg/kWh)
6.10.Concerns for Aerogels in EV Batteries and How They're Addressed
6.11.Applications of Aerogels in EV Batteries: IBIH
6.12.Applications of Aerogels in EV Batteries: Other Chinese Manufacturers
6.13.Current Applications of Aerogels in EV Batteries: Aspen Aerogels
6.14.Applications of Aerogels in EV Batteries: JIOS
6.15.Notable Entrants to the EV Market - Alkegen, Toray, and others
6.16.Notable Entrants to the EV Market - Cabot Corporation
6.17.Enersens developing Skogar range for EV and eVTOL
6.18.Blueshift's polyimide AeroZero based thermal runaway mitigation solutions
6.19.Combining Aerogels with Foams for EV and eVTOL applications
6.20.Examples of aerogel fire protection materials for EVs
6.21.Comparison of Aerogel Fire Protection Materials for EV Batteries
6.22.Forecast: Aerogel Fire Protection Materials for EV, eVTOL, and eCTOL
6.23.Forecast: Aerogel Material Demand for EV 2021-2035
6.24.For more information on Fire Protection Materials for Electric Vehicle Batteries
7.APPLICATIONS: THERMAL AND CRYOGENIC INSULATION
7.1.Building and Construction
7.1.1.Building and construction - overview
7.1.2.Building and construction - panels and blankets
7.1.3.Building and construction - coatings and paints
7.1.4.Building and construction - plaster, concrete and bricks (2)
7.1.5.Notable entrants: Aerogel startups targeting building insulation
7.1.6."Aerogel-like" products
7.1.7."Aerogel-like" products - SUMTEQ
7.1.8.Benchmark: aerogel density and thermal conductivity for building & construction
7.1.9.Benchmark: silica aerogels for building and construction applications
7.1.10.Benchmark: silica composite aerogels for building and construction
7.1.11.Benchmark: polymer aerogels for building and construction
7.2.Oil & Gas and Energy Infrastructure
7.2.1.Oil and Gas - refineries
7.2.2.Oil and Gas - pipelines
7.2.3.Benchmark: Aerogels for oil & gas refineries and pipelines
7.2.4.Oil and Gas - cryogenic insulation for pipelines
7.2.5.Examples of aerogel products for cryogenic insulation
7.2.6.District energy applications
7.3.Industrial Insulation
7.3.1.Industrial insulation
7.3.2.Examples of aerogel products for industrial applications from major players
8.APPLICATIONS: OTHER
8.1.Energy Storage
8.1.1.Energy Storage Overview
8.1.2.Energy storage - silicon anodes and Aspen Aerogels
8.1.3.Energy storage - Li-S batteries
8.1.4.Energy storage - carbon aerogels as electrodes
8.1.5.Energy storage - Graphene aerogels
8.1.6.Energy Storage: Supercapacitors
8.1.7.Energy storage: thermal insulation
8.2.Aerospace and Defence
8.2.1.Aerogels used in Stardust and Rover missions by NASA
8.2.2.NASA - Aerogels for Space and Beyond
8.2.3.NASA - PI aerogels
8.2.4.Examples of NASA's developments on aerogel applications for aerospace
8.2.5.Other examples of NASA's advances in PI aerogel applications for space
8.2.6.Other notable players developing aerogels for aerospace applications
8.2.7.Examples of aerogels for aerospace applications
8.2.8.Defence applications
8.3.Electronic Appliances and Telecoms
8.3.1.EMI shielding
8.3.2.Electronics - thermal insulation
8.3.3.Examples of aerogel products for electronic appliances
8.3.4.5G mobile phones - antenna modules
8.3.5.Antenna substrates - polymer aerogels
8.3.6.Low loss materials for 5G - polymer aerogels
8.3.7.Low loss materials for 5G - polymer aerogels (2)
8.4.Apparel & Sports
8.4.1.Apparel applications
8.4.2.Case study: Solarcore's aerogel for apparel applications
8.4.3.Examples of other aerogel products for apparel
8.4.4.Sports equipment
8.5.Daylighting
8.5.1.Window insulation - Cabot Corporation
8.5.2.Window insulation - AeroShield
8.5.3.Window insulation - Tiem Factory
8.5.4.Examples of aerogel products for daylighting
8.6.Transportation
8.6.1.Transportation - silica
8.6.2.Transportation - polymer aerogel
8.6.3.Aerogel products for transportation: new energy vehicles, railway, etc.
8.7.Other
8.7.1.Oil-spill remediation and desalination
8.7.2.Packaging - Cold chain
8.7.3.Personal care products: beauty ad cosmetics
8.7.4.R&D activities and other applications of aerogels
9.FORECASTS
9.1.Forecast Methodology
9.2.Aerogel Forecast 2021-2035: Polymer and Silica-Based Aerogels
9.3.Silica and Silica Composite Aerogel Forecasts 2021-2025: Applications/Sector
9.4.Silica and Silica Composite Aerogel Forecasts: Market share % by Application
9.5.Silica and Silica Composite Aerogel Forecasts: Industrial, LNG and Energy
9.6.Forecast: Aerogel Fire Protection Materials for EV, eVTOL, and eCTOL
9.7.Forecast: Aerogel Material Demand for EV 2021-2035
9.8.Comparison with Previous Forecasts
10.COMPANY PROFILES
 

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Aerogel market to grow at a CAGR of 12.2% between 2025 to 2035.

Report Statistics

Slides 228
Forecasts to 2035
Published Feb 2025
 

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