Light-weight ceramic aerogels hold promise for superinsulation. However, its mechanical instability and complex manufacturing hampered its technical applications. In this study, we demonstrate lightweight pore-gradient ceramic aerogel-like foam monoliths (PGAFoams) through one-pot and in situ bubble supported pore gradient formation. The mechanically strong PGAFoams exhibit a low thermal conductivity of 0.036 W m-1 K-1 and a compressive strength of 89.85 MPa. The pore gradient and integral ceramic monolith nature provides such hydrophobic PGAFoams with thermal management, robust soundproof, and fire-resistance performance. Highly machinable PGAFoams can be adapted into a variety of shapes and dimensions to accommodate complex geometry applications. The scalable manufacturing of lightweight PGAFoams opens up building insulation with remarkable thermal management, high mechanical strength, low mass density, superior soundproofing, and fire-retardant performances.
Keywords: Energy sustainability; pore-gradient manufacturing; thermal insulation.