Outlast Technologies has long been at the forefront of temperature regulation, developing efficient solutions for textiles, footwear, and bedding. By proactively managing heat, the company strives to enhance comfort and performance across various applications.

However, innovation comes with challenges. Developing aerogel-based insulation meant over-coming material limitations and production complexities. Similarly, advancing new cooling technologies posed difficulties in integration. Despite these hurdles, Outlast continues to make significant progress, pushing the boundaries of thermal management.

In this interview, Volker Schuster, Head of R&D, shares insights into the development process, key achievements, and the challenges that remain.

Innovation in Textiles (IiT): What are the biggest trends in temperature-regulating textiles, and how do you see consumer expectations evolving?

Volker Schuster (VS): One of the biggest trends in temperature-regulating textiles is the continuous innovation in how these technologies are integrated into fabrics. At Outlast, we do not rely on our proven temperature-regulating technology but are constantly researching new methods to apply and bind this technology to textiles in different ways.

Most recently, in collaboration with our production partner Liongtex, we won with our MIC process, the Performance Days Award in the Bodywear category. This innovative approach involves applying only an ultra-thin layer of our natural wax, the key component responsible for our temperature regulation. Despite this minimal impact, the performance remains highly effective, allowing customers to continue using their preferred materials while enhancing them with temperature-regulating properties.

IiT: What are the challenges in making temperature-regulating textiles more widely available, particularly in sustainable and affordable formats?

VS: Such challenges are solvable. A great example is fresh2SKIN, our technology designed for high-volume programs, enabling efficient and cost-effective large-scale implementation. By integrating fresh2SKIN via a dipping bath, we simplify the process, ensuring seamless application across a wide range of textiles. This not only makes temperature-regulating textiles more accessible but also supports sustainable production. As a bluesign-compliant technology, fresh2SKIN allows our brand partners to develop bluesign-certified products featuring Outlast Temperature Regulation. Through continuous optimization, we ensure our solutions remain scalable, high-performing, and environmentally responsible.

IiT: How does climate change influence the demand for temperature-regulating materials, and how is the industry adapting?

VS: Climate change and rising global temperatures are indeed increasing the demand for our temperature-regulating and cooling technologies. Smart clothing offers a much more efficient way to achieve a comfortable microclimate compared to other approaches. Since clothing is worn directly on the skin, it has a constant and immediate impact on our well-being.

IiT: Outlast has been a pioneer in temperature regulation since its NASA origins. How has your approach to R&D evolved over the years to stay ahead in the industry?

VS: NASA's research has continuously shaped and inspired our innovations. Our Aersulate technology, for instance, is based on Aerogel - the world's lightest solid. This remarkable material, also used by NASA, stands out due to its high air content and exceptional insulating properties, making it the perfect basis for highly efficient insulating materials and fibres.

IiT: Aersulate is described as a revolutionary insulation material. What were the biggest technical challenges in developing it, and how does it differ from traditional insulation?

VS: One of the biggest challenges was simply getting the material to stay where we wanted it (laughs). Due to its incredible lightness, Aerogel tends to disperse into the air instantly unless it is bound immediately - which, as you can imagine, was no trivial task.

What makes Aersulate truly unique compared to traditional insulation materials like felt, wadding, or fleece is that it maintains its insulating properties even under pressure. While conventional insulations lose their effectiveness when compressed, Aersulate fabrics trap air within their porous Aerogel structure, preventing heat loss even under compression.

Additionally, moisture has minimal impact on our insulation. Unlike standard materials where insulating air mostly escapes due to humidity, the air within Aerogel particles remains locked in, ensuring consistent thermal performance. As scientists, we are certainly excited to have developed something genuinely new and ground-breaking in the field of insulation.

IiT: Sustainability is a key focus for Outlast. How do you balance innovation in thermo-regulation with environmentally friendly materials and processes?

VS: Often, it works the other way around - the desire for sustainability drives innovation. For example, through extensive research and development, we successfully transitioned the wax used in our temperature-regulating technology entirely to plant based natural wax. This was a significant challenge, but ultimately, we achieved it, allowing us to make a meaningful contribution to more sustainable products and the responsible use of finite resources.

IiT: Can you share insights into the development of Outlast’s proactive heat management technology? How do you see it evolving in the next decade?

VS: Some innovations don’t need to be developed from scratch - they already exist but lacked a way to be measured. This was the case with the cool-touch feel of our temperature-regulating materials. Everyone could perceive the pleasant cooling effect, but until now, it was not quantifiable. With the help of high-tech equipment following ASTM standard D7984, we can now accurately determine the so-called effusivity value of textiles.

Our findings show that a raw material’s effusivity can increase by up to 60% with the application of Outlast Temperature Regulating technology. Naturally, this drives sales, as our brand partners leverage these precise values in their marketing. To further support our customers, we now offer effusivity testing free of charge, reinforcing our commitment to transparency and innovation.

IiT: How do you test and validate the performance of Outlast materials to ensure they meet industry and consumer expectations?

VS: Transparency and scientific precision have always been part of Outlast's DNA. According to our guidelines, no temperature-regulating Outlast product reaches the market without undergoing extensive performance testing. We utilize highly precise and advanced testing equipment, ensuring reliable and accurate results that meet the DIN EN 16806-1 standard. This rigorous validation process guarantees that our materials consistently deliver the performance expected by both the industry and consumers.

IiT: With Outlast materials being used in various industries - from apparel to bedding - how do you customise solutions for different applications?

VS: We are the market leader in temperature-regulating materials for a reason - we simply know this field best (smiles). Our deep expertise allows us to provide highly tailored and well-founded consulting, ensuring that each industry and application gets the most suitable solution. A one-size-fits-all approach is not our philosophy. Instead, we work closely with our brand partners to customize materials based on specific performance requirements, whether for apparel, bedding, footwear, or technical applications. This flexibility ensures that our temperature-regulating technology meets the unique demands of every industry we serve.

IiT: What is the process of integrating Outlast technologies into products with brand partners, and how do you ensure quality control across supply chains?

VS: The secret to Outlast’s success lies in our close collaboration - both with our brand partners and production partners. Our customers appreciate working with us because they see firsthand how our expertise enhances their products. At the same time, we maintain strong relationships with our production partners, ensuring that everyone is aligned toward the same goal: delivering high-quality, performance-driven solutions. This win-win situation fosters a high level of commitment on all sides. Our exceptionally low complaint rate - well be-low single-digit percentages - speaks for itself and reflects our rigorous quality control measures across the entire supply chain.

Outlast temperature regulating fibres video…

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