Ceramic Fiber–Functionalized Silica Aerogel Coating for Lightweight Thermal Protection of UAVs in Extreme Environments

ABSTRACT Unmanned aerial vehicles (UAVs) have emerged as versatile tools in civil applications, including agriculture, environmental monitoring, search and rescue, and infrastructure inspection. However, UAVs are complex and sensitive electronic systems that are vulnerable to extreme environments, and their operation at very high temperatures remains challenging. In this study, ceramic fiber–functionalized silica aerogel (CFSA) coatings were designed for enhanced fire protection in UAVs. CFSA integrates silica aerogel with ceramic fibers, providing excellent thermal insulation, flame retardancy, mechanical strength, and low density, which make it suitable for UAV applications without significantly affecting flight performance. CFSA exhibits a low thermal conductivity of 0.032 W·m −1 ·K −1 and a compressive modulus of 2155.7 kPa, indicating effective thermal insulation for protecting temperature‐sensitive UAV components while maintaining structural integrity at temperatures above 1300°C. Additionally, CFSA exhibits impressive UV stability and hydrophobicity, which make it suitable for long‐term application in harsh environments. Simulation results demonstrate that CFSA effectively shields sensitive components, particularly UAV batteries, from high temperatures. In summary, the CFSA coating not only provides outstanding flame retardancy and prevents substrate combustion, but also maintains low internal temperatures during high‐heat exposure, offering a robust solution for thermal protection in industrial and aerospace applications.