Zircotec has launched what is believed to be the first-ever flexible ceramic heat shield material. The new material ZircoFlex^TM has been demonstrated to offer superb thermal barrier performance at minimal weight and minimal thickness. ZircoFlex^TM is supplied in the form of a roll, and is set to revolutionise the use of ceramic materials for heat protection in a wide range of automotive, aerospace and industrial applications. It has already been supplied as a pre-production product to F1.

ZircoFlex^TM is based on a technology that has been developed by Zircotec to allow flexible ceramic coatings to be supplied as a thin aluminium backed foil. The new material, for which a patent has been applied for, is lightweight at only 460g/m² and only 0.25mm thick. ZircoFlex^TM foil is however robust and easy to handle. It can be cut and installed by hand or machine, and is easily fixed in place using mechanical fasteners or high temperature adhesives (also supplied by Zircotec), allowing it to be integrated directly into conventional production or maintenance operations.

Ceramic coatings are naturally relatively brittle, which has limited their use up until now to rigid substrates. The new ZircoFlex^TM product, which is the culmination of more than five years' intensive research and materials science, uses a new technology in which the ceramic material is sprayed in the form of thousands of individual ‘platelets' on the surface of the foil. While they are close-packed to provide comprehensive heat protection, this structure allows the foil to be bent and manipulated to suit different geometries, and it can even be folded tightly through 180^o without damaging the thermal barrier.

"ZircoFlex^TM has the potential to transform the use of ceramic heat protection," says Zircotec sales director Peter Whyman. "For the first time these coatings can be installed in-line to parts and assemblies during manufacture, even in high volume applications, without disrupting production flow. The potential in maintenance and aftermarket applications is huge too. Users can now upgrade parts with Zircotec ceramic protection without needing to dismantle or decommission their equipment."

Early applications for ZircoFlex^TM foil are expected to come from the automotive industry, where the foil can be used to protect sensitive components from heat in increasingly crowded engine bays.

Zircotec has also experienced considerable interest from the motorsport sector where the foil is in demand as a rapid solution to thermal protection problems. The company is continuing its research into flexible ceramic coatings and has plans to produce an expanded range of ZircoFlex^TM foils using a range of alternative substrates.

Zircotec's Tom Prentice is the lead man behind the development of the ZircoFlex^TM product line. Tom is shown here holding a sample of ZircoFlex^TM whilst he is presented with a bottle of champagne to mark the early achievement of Zircotec's initial sales targets for ZircoFlex^TM.

Click here for further details on ZircoFlex^TM.

Tom Prentice (left) being presented with a bottle of champagne by Zircotec's Managing Director, Terry Graham (right).