Outlast to exhibit aerogel-based Aersulate Wadding at Performance Days

Outlast Technologies is showcasing Aersulate Wadding – its NASA-inspired, fiber-based insulation – at PERFORMANCE DAYS Munich. Recognized among the Top Ten in the show’s Innovation Forum, Aersulate was selected from over 2,000 fabric submissions, standing out to the jury for its high thermal efficiency with low volume.

At the core of Aersulate is aerogel – the world’s lightest solid, consisting of up to 99% air. Outlast embeds an impressive 50% by volume of aerogel directly into viscose fibers, creating an insulation that is exceptionally light yet extraordinarily effective.

Outlast Technologies is presenting Aersulate Wadding—NASA-inspired insulation made from viscose fibers embedded with 50 per cent aerogel by volume—at Performance Days Munich.
Named among the show’s Top Ten innovations, it delivers up to 37 per cent higher thermal efficiency and maintains warmth even under compression.
Aersulate offers a sustainable, animal-free alternative to down and synthetic fills.

Proven Performance

Independent lab data confirm a significant increase in thermal efficiency versus conventional solutions:

• +35% higher RCT values in wadding
• Up to +37% higher RCT in needlefelt applications
• Same warmth at up to 35% less volume (no extra bulk)

Performs Under Pressure

Aersulate Wadding delivers warmth precisely where traditional wadding loses effectiveness – under compression. Air is an excellent natural insulator, but in conventional fills it is squeezed out when pressure is applied (e.g., kneeling or sitting), causing thermal performance to drop. With an exceptionally high aerogel content – 50% by volume – Aersulate stores air within a stable, porous microstructure that keeps it from escaping. The result is consistently high insulation – even under compression and in humid conditions. From outerwear and ski apparel to technical workwear, Aersulate reliably sustains thermal performance.

Sustainable by Design

Aersulate Wadding unites aerogel made from quartz sand with renewable, wood-based viscose to offer a sustainable, animal-free alternative to down and conventional synthetic fills – with no compromise on performance.

“With our patent-pending fiber technology, Aersulate redefines what textile insulation can be: thin, light, and powerful,” said Ari Pachur, Senior Business Development Manager Over-seas of Outlast. “Being selected for the Top Ten out of more than 2,000 entries at PERFORMANCE DAYS is a fantastic recognition of what this technology enables.”

See It at PERFORMANCE DAYS Munich

Experience Aersulate Wadding firsthand at PERFORMANCE DAYS Munich, taking place 29–30 October 2025 at Booth L19.

Learn why Aersulate has been selected for the Innovation Forum “Top Ten” showcase, and meet the Outlast team on site to explore its wide range of applications.

Note: The headline, insights, and image of this press release may have been refined by the Fibre2Fashion staff; the rest of the content remains unchanged.

Fibre2Fashion News Desk (MS)