Lightweight Insulation Polymer Aerogels in Orbit

Image from NASA

What are polymer aerogels and why they matter

Results published in April 2025, by NASA researchers at Glenn Research Center into how polyimide-based aerogels perform in low-Earth orbit, showed minimal degradation in key properties following atomic-oxygen exposure.

Aerogels are ultra-light porous materials that combine ultralow density with outstanding thermal insulation and vibrational damping, which makes them highly interesting for a wide number of applications in spacecraft thermal control, habitat construction, and protection in extreme environments.

Space-specific testing and results

On the one hand, it was revealed that high-density aerogel samples only lost about 1.5% of thickness due to erosion (50 µm), while the lower-density analogs lost 5% (150 µm) after space exposure.

IR spectroscopy showed the presence of new ether (C-O-C) bonds, indicating atomic oxygen effects. However, material mechanical and thermal properties were not significantly different from those in as-received conditions. This means that aerogels may be viable for more extended missions in orbit or on lunar/Martian surfaces.

Implications for future missions

In addition, because many materials for spacecraft applications have to be low mass with high insulation properties, polymer aerogels create possibilities for lighter-weight thermal shields, insulation layers, and multifunctional structural parts. Durability in orbit indicates that the application is shifting from concept toward practical realization. Missions going farther and longer require such advanced materials to minimize launch mass and to ensure performance under extreme environmental conditions.