Scalable multi-stage spinning of weavable high temperature resistant SiNAFs@PSO/Aramid composite aerogel fibers

SiO₂ aerogel fibers are widely regarded as one of the lightest solid materials, exhibiting exceptional thermal insulation properties. However, achieving both high elasticity and spinnability remains a significant challenge in the fabrication process. A scalable and efficient vortex-assisted multi-stage spinning strategy has been employed to fabricate Silica Nanofiber Aerogel Fibers@Polysiloxane/Aramid Aerogel Fibers (SiNAFs@PSO/Aramid). These fibers are characterized by a hierarchical architecture, consisting of an interwoven SiO₂ nanowire aerogel network as the core and a robust PSO/Aramid composite shell. SiNAFs@PSO/Aramid demonstrate ultralow density (<0.15 g/cm³), exceptional mechanical resilience (tensile strength >4 MPa), and an ultra-low thermal conductivity of 0.033 W/m·K, outperforming conventional thermal insulation materials. Mechanical integrity remains stable under extreme thermal ranging from -196 °C to 500 °C, ensuring durability in harsh environments. Superior weaveability enables the fabrication of highly adaptable, three-dimensional foldable textiles with tunable geometric configurations. Upon exposure to high temperatures, an in-situ transformation into SiOC ceramic composites occurs, significantly enhancing thermal shock resistance and mechanical stability. Flexibility and geometric adaptability of these aerogel fabrics make SiNAFs@PSO/Aramid well-suited for applications requiring diverse shape configurations, as well as high-temperature thermal insulation.