Material definition
Approved material grade, complete layer stack, adhesive, carrier and liner recorded against the customer drawing
Custom product
Custom Aerogel Thermal Barrier Parts
Thin, lightweight aerogel-based insulation parts considered for space-constrained UAV and robotic battery or power assemblies where thermal separation is required.
Custom die-cutMulti-layer laminationPrototype supportDocumented inspection
Function
What this component solves
Adds a low-profile thermal-resistance layer between defined surfaces while fitting the customer’s geometry and assembly method.
Typical install positions
- Between battery cells or modules
- Battery-to-housing interface
- Power electronics separation
- Temperature-sensitive component boundary
- Pack lid or sidewall
Engineering selection
Data your engineering team can specify
We define the finished part around the selected material grade, test basis, drawing and assembly conditions. The items below can be included in the project review and data package.
Typical screening rangeCustomizable by FLEXCENDGrade-specific data availableAssembly validation required
Data pointWhat FLEXCEND can define or provide
Finished thicknessRepresentative thin barrier review window: 0.50–6.00 mm, depending on core, facing and encapsulation
Thermal conductivityRepresentative aerogel core or blanket range near room temperature: about 0.012–0.030 W/m·K; test method and compression must be stated
DensityRepresentative lightweight blanket/core range: approximately 70–200 kg/m³ before added facings or frames
Thermal resistanceCalculated from the complete thickness and grade, then checked under the intended compression and temperature exposure
Edge / dust controlFilm, paper, mica or elastomeric encapsulation can be reviewed around particle control and assembly
Event performanceTorch, flame and propagation evidence is quoted only for the exact barrier construction and customer test method
Thermal conductivityGrade-specific data supplied with thickness, temperature and test method identified
Thermal resistanceComplete barrier stack reviewed rather than quoting aerogel core data alone
Density / areal weightFinished part mass calculated for lightweight UAV and mobile-robot programs
Temperature exposureContinuous, peak and test exposure limits confirmed for core, film, adhesive and encapsulation
Electrical insulationDielectric behavior confirmed from the complete selected construction where required
Dust, edge and flame behaviorEncapsulation, particle control and flammability documentation reviewed by exact grade
How to read these values: Published ranges are representative design-screening windows across material families FLEXCEND can source, convert and evaluate. They are not one universal finished-part specification. Final values are confirmed against the exact grade, thickness, adhesive stack, test method, approved drawing, production lot and complete customer assembly.
Representative sample
See the material and converted geometry.
This image was extracted from the supplied product library and shows a representative part family. Exact material, grade, thickness and dimensions are defined by the approved drawing and material specification.
Engineering evidence
A project data package—not a generic material claim.
The exact content is agreed by program. Performance values stay linked to the selected material, thickness, method and test condition.
Performance evidence
Supplier TDS or relevant test data tied to the selected grade, thickness, method and test condition
Dimensional control
Critical dimensions and tolerances reviewed against material behavior, part geometry, tooling and process route
Prototype / first article
Fit samples, comparison sets and dimensional reporting can be agreed before production release
Compliance documents
RoHS, REACH, halogen, flammability or other declarations supplied only when supported by the exact selected material
Traceability and delivery
Drawing revision, material or production lot, inspection plan, liner format, kitting and packaging defined by program
Made to drawing
Configure the complete part—not just the base material.
We review how material, adhesive, liner, lamination, geometry and delivery format work together at assembly.
- Protective film or encapsulation review
- Adhesive frame or mounting features
- Custom cell or module outline
- Lamination with insulation film
- Piece or array format
- Prototype handling evaluation
Fast technical response
Send the inputs engineers use to make a real selection
A drawing plus these operating conditions lets us recommend a practical construction instead of a generic material.
- Heat source, protected surface and event duration
- Available thickness and weight target
- Operating and peak temperature
- Electrical-isolation requirement
- Dust-control, encapsulation and assembly need
- Part drawing, prototype test and validation standard
Engineering boundary
No thermal-runaway containment or pack-safety guarantee is made from a barrier material alone. Selected materials and the complete pack must be validated against the customer’s safety requirements.
Application fit
Where this product is commonly considered
application
UAV Battery Protection
Custom lightweight spacing, cushioning, insulation and thermal-interface parts for UAV battery packs designed by the customer’s battery engineering team.
Explore
Manufacturing path
Slit, laminate, die-cut and inspect.
Prototype and production methods are selected around the material behavior, geometry, laminated stack and program volume.
See factory capabilitiesEngineering review
Request a custom aerogel thermal barriers review
Tell us the installation position, material challenge, environment and project stage. Our team will review the drawing and recommend a practical construction.