HEATLOCK® / AERO
AERO
ULTRA-LIGHT THERMAL PERFORMANCE.
Silica aerogel — the world's lightest solid — embedded directly into virgin or recycled polyester fibers at the molecular level. Insulation that disappears into the garment.
4.46 CLO
VALIDATED THERMAL RESISTANCE
>90%
AIR BY VOLUME IN AEROGEL
0.9d–2.5d
FIBER SPEC RANGE
60–200 g/m²
PADDING WEIGHT RANGE
WHAT IS HEATLOCK® AERO ?
AEROGEL, AT THE FIBER LEVEL
HEATLOCK® AERO is an advanced and complete insulation technology that embeds silica aerogel — the world's lightest solid and one of its most efficient insulators — directly into virgin or recycled polyester fibers.
Composed of over 90% air, aerogel's ultra-porous structure restricts heat transfer by minimizing conduction and convection. When integrated at the fiber level, this creates a micro-porous thermal matrix that traps warmth with minimal weight or bulk.
Engineered for high-performance environments, HEATLOCK® AERO delivers exceptional thermal efficiency, breathability, and long-wearing comfort without compromising durability. Unlike surface treatments, the aerogel particles are permanently embedded within the fiber, offering insulation that lasts through repeated use and wash cycles — while remaining soft, feather-light, and breathable.
HEATLOCK® / AERO
A MICROPOROUS MATRIX THAT TRAPS WARMTH.
HEATLOCK® AERO uses ultrafine powdered silica aerogel embedded directly into polyester fibers during melt spinning. This forms a microporous matrix that traps heat, blocks cold air, and minimizes thermal conductivity without added bulk.
Because the aerogel is infused into the fiber itself — not coated — the insulation remains breathable, durable, and effective even after repeated wear and washing.
COMPOSITION
WHAT'S INSIDE.
0.5–1.5%
SILICA AEROGEL (SiO₂)
Proprietary aerogel matrix, by weight.
Optimized for thermal insulation and textile integration.
UP TO 99%
AIR BY VOLUME
Encapsulated within aerogel's porous nanostructure.
The reason it insulates so efficiently.
PET / NYLON
CARRIER FIBER
Virgin or recycled polyester base. Nylon carrier available for select applications.
PRODUCT FORMATS
AERO is available across four production formats — integrate it at whichever stage fits your supply chain.
FIBERS
Specs: Ultra-fine 0.9d × 25mm to heavy-duty 2.5d × 51mm / 3D × 64mm. TraceLock™ available on 0.9d.
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Winter outerwear
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Performance gear
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Bedding
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Thermal blankets
EXCEPTIONAL INSULATION · LIGHTWEIGHT · BREATHABLE
YARNS
Specs: 50D, 75D, 100D, 150D. Compatible with standard knit and woven processes.
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Base layers
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Activewear
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Smart textiles
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Thermal underwear
SEAMLESS INTEGRATION · VERSATILE · MOISTURE MANAGEMENT
FABRICS
Specs: Knit and woven constructions. Ready for cut-and-sew workflows.
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Fleece jackets
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Thermal layers
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Sports apparel
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Outerwear
IMMEDIATE APPLICATION · CONSISTENT · COMFORTABLE
PADDING
Specs: 60g/m² to 200g/m². Custom weights available. Produced with Imbotex S.R.L.
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Winter coats
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Extreme weather gear
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Sleeping bags
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Flock applications
CUSTOMIZABLE · CONSISTENT · EASY TO PROCESS
TRACELOCK™ ON HEATLOCK® AERO
AUTHENTICITY, EMBEDDED.
TraceLock™ is HeatLock's proprietary fiber-level tracer — a precision-controlled elemental signature embedded directly into the AERO fiber matrix at 0.05–0.10% by weight. Lab-verifiable via XRF, SEM-EDS, or ICP-MS. Patent pending.
Availability: Currently included on HEATLOCK® AERO 0.9d × 25mm fiber only, through authorized partners. Expanding to additional specs in future production runs.
ALSO IN THE FAMILY
TWO MORE HEATLOCK® VARIATIONS
Where AERO is engineered for ultra-light thermal performance, our family also includes two specialized variations designed for movement, moisture, and lightweight efficiency.
THERMAL RETENTION WITH MOISTURE BALANCE.
Dual-action fiber engineering — heat held in, moisture moved out.
Built for activewear, cold-weather movement, and dynamic environments where warmth and breathability both matter.
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Dual-action heat + moisture management
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Activewear, outdoor apparel, workwear
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Designed for dynamic environments
THERMAL RETENTION WITH MOISTURE BALANCE.
Hollow-core filament construction traps insulating air within each fiber while integrating proprietary insulative elements in the sheath — reducing overall material weight by up to 30%.
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Hollow-core filament architecture
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Up to 30% lighter than comparable fibers
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Cost-efficient thermal applications