Public Funding for Dragonfly Insulation Ltd

Dragonfly Insulation Ltd (DF) is a UK-based advanced material manufacturing company that specialises in aerogel technologies. This project builds on the successful IUK ICURe project which has taken DF's silica aerogel manufacturing process from laboratory to small scale production. Silica aerogel is an extremely light, highly thermally efficient insulation material that is stable at high temperatures. Previously used by NASA and space programmes, it is an insulation material of the future with the potential to significantly impact on the thermal efficiency of our homes, of industry and the achievement of NetZero. The project will build on DF's patented processes to develop a scaleable, resource efficient, modularised manufacturing process to efficiently scale production of silica aerogels, up or down, without disrupting the process, through a system of interchangeable modules that can be added to, removed, or modified to meet production and product application needs. Incorporating energy exchange systems to capture and repurpose waste energy will reduce energy consumption and manufacturing costs, addressing the need for sustainable manufacturing as we strive towards NetZero. The proposed project aligns with the Innovate UK plan for action and has the potential to have a significant impact on the future economy areas of the broader theme of NetZero.

Aerogels are the most porous and thermally efficient materials known to man. They are used in space exploration including the capture of high-speed star-dust, cryogenic insulation for space launch vehicles and thermal insulation for Mars rovers. With their outstanding insulation properties, aerogels have great potential to be commercialised, but until now the high cost of manufacturing has prohibited their use in domestic applications. Aerogel companies working on these developments are addressing some of the major challenges facing the world over the coming decades, such as energy-efficient manufacturing processes and materials to promote energy efficiency. Many of these applications rely on the use of aerogels manufactured through a high-pressure-process or through an environmental-pressure-process with a large amount of high-cost organic drying solvent. The cost of commercial aerogel is still high due to the requirement of special pressurised chambers and high-energy consumption and/or a large amount of expensive organic solvent and is, therefore, a significant bottleneck to the future commercial potential of companies that produce or use aerogel products. Whilst there is an emerging demand for aerogel products both the traditional high-pressure manufacture of aerogel and environmental-pressure manufacture of aerogel (using high-cost organic solvent) can never practically meet the demands of the market. Currently, there is no aerogel manufacture in the UK. At Dragonfly Insulation Ltd, we aim to establish an innovative manufacturing facility for aerogels (powder/granules) in the North East of England. Our novel approach is to move from the traditional high-pressure/high-solvent-cost manufacturing process to a simple environmental pressure manufacturing process where aerogels are produced with low-cost water-based drying solvent. Our innovation facilitates such an approach for the first time. In light of this, the current proposal will enable the setting up of Dragonfly Insulation Ltd as a business hiring qualified team members, renting manufacturing/office space, paying for consultancy, legal costs and further market research. Accelerating the company's development at this stage will help Dragonfly Insulation Ltd to attract private investors for the initial development and sales of its products.