Aerofonit

Aerofonit is a synthetic composite material first reported in the early 21st century in a series of engineering theses focused on lightweight aerospace structures. It is produced through a multi-step polymerization process that incorporates aerogel-derived silica frameworks with a high-performance thermoplastic matrix. The resulting material exhibits an exceptional strength-to-weight ratio, comparable to aluminum alloys while being roughly one third of the density.

The development of aerofonit was driven by the demand for energy-efficient aircraft skins and satellite components that can withstand the thermal extremes of space. In laboratory tests, aerofonit demonstrates a tensile strength of about 200 MPa and a compressive modulus of 5 GPa, with a thermal expansion coefficient close to 10 × 10⁻⁶ /°C. Its low thermal conductivity, on the order of 0.06 W/m·K, provides inherent insulation against radiative heat transfer.

Manufacturing aerofonit involves solvent-free extrusion and 3D printing methods, enabling complex geometries without compromising structural integrity. Its porosity allows for controlled airflow, making it suitable for heat exchangers and noise-dampening panels. In addition, aerofonit’s surface can be functionalized with nanocoatings to increase resistance to ultraviolet radiation and corrosion.

While commercial adoption remains limited, prototypes of aerofonit-based fuselage panels have been flight-tested on unmanned aerial vehicles, achieving a weight reduction of 25 % compared to conventional aluminum skins. Ongoing research explores its integration into hybrid wing- body designs and reusable space launch vehicles.