Aerogels are often described as 'frozen smoke' because these extremely light materials are composed mostly of air. Their tiny pores give them a very low weight, strong insulating properties, and a huge surface area compared to their size. They are widely used in construction, but their real potential extends much further. Through the COST Action Advanced Engineering and Research of aeroGels for Environment and Life Sciences (AEROGELS), researchers explored applications that were previously unknown, ranging from environmental uses to biomedical and food innovations.
The Action brought together scientists, engineers and industry experts who had never collaborated before. It created a strong European network that pushed aerogels into the spotlight with new discoveries, growing global recognition and ideas that reshaped the field.
The momentum created during the Action led to the COST Innovators Grant (CIG): Technical, commercial and societal innovations on aerogels towards circular economy (ECO-AEROGELS). Its aim was clear: to use the Action's achievements as a springboard to make aerogels more sustainable, more practical and more accessible. The grant also helped the creation of the International Aerogel Association, enabling the community to continue growing beyond the lifetime of the Action.
Aerogels were invented in the 1930s and first tested for aerospace and construction Aerogels can be made from different sources (inorganic, organic, hybrid) Aerogels come as solid blocks, tiny beads or powders and can be designed to attract or repel water Aerogels have 15 Guinness World Records including the lightest material of the world
A Community That Transformed an Entire Field
When AEROGELS started in 2019, most people saw aerogels as impressive but delicate niche materials. The COST Action changed this perception. With its community of 600 researchers from 47 countries, Europe became the driving force behind efforts to make aerogels more environmentally friendly and useful to society.
Research activity increased rapidly. Aerogels were selected by the International Union of Pure and Applied Chemistry (IUPAC) as one of the Top Ten Emerging Technologies in Chemistry. The field advanced so quickly that IUPAC is considering to revisit its own definition of aerogels. A collaboration supported by the Action even resulted in a Nature publication on 3D-printed silica aerogels, opening new possibilities in robotics, electronics, and medicine.
A key moment came when engineers and technology groups joined the network. Their industry experience helped researchers to understand how to scale up production and design market-ready products. In turn, companies learned how aerogels could solve everyday problems. Reflecting on these exchanges, Professor Carlos García-González from the University of Santiago de Compostela, the Action Chair, explains:
"As a result of this close contact and collaboration between academia and industry, two business models were defined and are on the way to acceleration with funding acquisition actions for the ulterior establishment of two new start-ups."
Turning Ideas into Solutions
The momentum created during the Action resulted in a new milestone: the ECO-AEROGELS COST Innovators Grant (CIG). Building on the results of the Action, the CIG shifted the focus from discovery to real-world impact. Carlos describes the approach:
"During the ECO-AEROGELS CIG, several approaches were developed. In terms of green production, alternative sources of aerogel precursors from waste, food leftovers and forest residues were evaluated and integrated into the aerogel production pipeline. Alternative green aerogel production methods were also tested to minimize raw material and energy consumption and reduce waste, including 3D printing of aerogels and continuous aerogel processing."
"This research is the tip of a huge iceberg that warrants further exploration beyond the CIG lifetime." Prof. Carlos García-González Chair of AEROGELS and ECO-AEROGELS
Two Breakthrough Results Stood Out
Breakthrough One: Aerogels Ready for Medicine
A significant achievement was the development of sterile aerogels made from natural polymers. Previously, aerogels could be used in medicine but sterilizing them was difficult and often damaged the material. The team overcame this challenge by creating both a method and a working prototype that produces naturally sterile aerogels.
"This solution unlocks previous biomedical restrictions of aerogels and allows unprecedented uses of these materials where sterility is a critical quality attribute," says Prof. García-González.
This research won the Technology Transfer Prize 2025 from the Galician Royal Academy of Sciences. A patent for the sterilization process was filed during the CIG and has since been extended internationally. This marks a strong step towards real clinical applications.
Carlos García-González adds:
"In terms of circularity, this patent allows the production of sterile aerogels as well as the other new options for the reprocessing of aerogels and their safe disposal."
Breakthrough Two: AiryBerry - a Snack With a Story
"AiryBerry is a smart, sustainable, and nutritious way to rethink modern food!" Prof. Patrina Paraskevopoulou ITC Core Group Coordinator of AEROGELS
The second breakthrough took aerogels into an unexpected area: food. Using surplus fruit and by-products from the food industry, the team developed edible aerogels and created AiryBerry, a light, nutritious snack with a long shelf life. At a public tasting event in Athens, chefs, nutrition experts and food industry representatives sampled strawberry, coffee and oat versions. Many were surprised by the texture and taste. Professor Patrina Paraskevopoulou, one of the Action leaders from the National and Kapodistrian University of Athens, who organized the event, sums it up well:
"AiryBerry is a smart, sustainable, and nutritious way to rethink modern food!"
For developing the eco-innovative food product AiryBerry, a team of students from the Chemistry Department of the National and Kapodistrian University of Athens won 3rd prize at the ECOTROPHELIA 2023 competition. AiryBerry is now protected by a patent and has attracted strong interest from the food innovation sector. Prof Paraskevopoulou explains why this matters:
"This patent supports the valorization of surplus agricultural produce and by-products of the food industry into high-value aerogel-based functional food formulations, thereby promoting resource efficiency and sustainable food innovation."
A Legacy That will Last
Both the Action AEROGELS and the CIG ECO-AEROGELS have left a lasting mark. The scientific community formed during the Action continues to collaborate, and new teaching materials are being used in universities. The International Aerogel Association, which was founded in 2024, is continuing to shape this growing field. Meanwhile, the CIG has delivered patents, prototypes and new business opportunities that are bringing aerogels closer to everyday life. Several start-ups focusing on aerogel technologies have been established as a direct result of collaborations initiated during the Action.
Carlos offers a final reflection:
"The closed-loop recycling of aerogels and the reprocessing of aerogels have been identified as new and unexplored development pathways. This research is the tip of a huge iceberg that warrants further exploration beyond the CIG lifetime."