Energy & Power, Heating, Cooling & Drying

Ultra-light, high-performance flame & thermal barrier for next-gen electric and aerospace systems

Phil Black - PII Editor 09/11/2025

361 2 minutes read

Listen to this article

Blueshift, the technology leader in advanced thermal protection systems (TPS) has announced its latest offering: the AeroZero® Flame & Thermal Barriers (FTBs).

This portfolio of ultra-thin, lightweight and flexible flame and thermal material solutions is capable of withstanding exposure up to 1,200 °C for 30 minutes.

With the continuing global adoption of electric vehicles (EVs) and aerospace electrification, Blueshift’s newest addition to its AeroZero® family is ideal for a wide range of industries and applications that experience extreme temperature fluctuations, from EVs and aerospace markets to marine and rail sectors.

In the EV sector, for example, FTBs are primarily used as safety barrier materials designed to prevent the transfer of extreme heat or fire that can cause mechanical damage to battery cells and exposure to high temperatures or discharge events.

Blueshift’s AeroZero® FTBs can withstand exposure up to 1,200 °C for 30 minutes whilst maintaining a cold-side temperature below 300 °C. This performance means they can be used either as safety features to mitigate uncontrolled fire (e.g., due to an aircraft engine fire) or to protect surfaces from direct exposure to flame (such as during a rocket take-off), or help reduce the risk of a battery thermal runaway event.

Outperforming traditional materials such as mica, silica or polyurethane foams, AeroZero® FTBs are up to 80 % lighter, with a thickness range of 0.32 – 1.77 mm, significantly thinner than conventional barriers (typically 3-10 mm).

Alongside this, their ease of use and flexibility is a key factor influencing engineers’ decisions to integrate the new materials into their designs. With their “peel-and-stick” pressure sensitive adhesive (PSA) backing that simplifies installation on irregular surfaces, labour time and cost can be significantly lowered.

Tim Burbey, President at Blueshift, says that AeroZero® FTBs aim to set a new benchmark in the industry:

“Traditional thermal insulators have often been based on polymeric foams or ceramic blankets that can suffer from drawbacks due to their added weight, thickness, toxic off-gassing, lack of flexibility and processing issues. As EV adoption ramps up alongside aerospace electrification, our AeroZero® FTBs will unlock new performance capabilities by enabling the next generation of aircraft and vehicles to be safer, lighter and more efficient.”

“Available across multiple ranges, we look to incorporate as many vehicles and industries as possible, so everyone can overcome their unique thermal challenges that other FTBs in the market simply cannot.”

The AeroZero® FTB family includes:

AZ-FTB 100 for up to 500 °C applications
AZ-FTB 101 for up to 800 °C
AZ-FTB 300 for maximum protection up to 1,200 °C

These advanced FTBs are ideal for protection in EV battery modules, aerospace components exposed both indirectly and directly to flames, and other demanding environments.

For more detailed specifications or datasheets please visit the Blueshift website at or learn more about Blueshift