Technology Driven ·  Warfighter Focused

Pop-Up BioInsulation

U.S. ARMY MANTECH»Click to View/ Print Brochure


To reduce fuel and logistics costs by fielding lighter, more compact thermal liners with high R-value, a measurement of thermal resistance. The new insulation uses multiple layers of air cells that can be collapsed during packing by 10x. Warwick Mills is improving manufacturing and machining processes to increase production rates of this novel system, moving from a manual to an inline roll-to-roll production, thereby decreasing manufacturing costs.


• Improved R-value of insulation material to 5.7 on production samples in panel testing
• Demonstrated pre-pilot equipment capabilities and ran pilot production
• Further accelerated Thermal-Liner production by introducing in-line pilot lamination of cellular insulation layers, increasing productivity
• Increased Manufacturing Readiness Level (MRL) from MRL 4 to MRL 6
• Successfully designed and fabricated eight complete fullscale prototype thermal liners
• Conducted testing on full-scale prototype liners in both hot and cold weather to evaluate thermal liners
• Succeeded goal of greater than R-Value 5 installed in shelter, and achieve greater than R-Value 7 using production material


• System has fire-retardant integrated intrinsically within the material
• Dramatically improves the acoustics of the shelter, providing a better environment for the Soldier
• Reduced attachment system for easier installation, and no new attachment points required on shelter itself
• Reduced panel count for insulation system by increasing panel size, resulting in fewer item count, less assembly steps and improved logistics
• Significant reduction in Environmental Control Units (ECU) fuel requirement reduces logistical burden for basecamps
• Reduced volume from 100 ft^3 to 40 ft^3
• Increased fuel savings by 1.7 gallons/day in moderate temperatures (40º F outside) maintaining shelter inside at 70º F compared to current fielded insulation

Transition and Weapon Systems / Secondary Items Impacted

• Force Provider

If this is your first visit, please read our Security Disclaimer: All Web surfers are welcome at the U.S. Army ManTech Website and it is important that you understand the following: This is an official United States Government Information System for authorized, unclassified use only. The system is monitored to ensure information security, system integrity, and the limitation of use to official purposes. Parts of this server are available for use by non-DoD individuals. Some links on this website are locked. (If the area is locked there will be a notation to that effect next to the appropriate link). Your use of this system is subject to monitoring at all times. Unauthorized or illegal activities, involving this system, can result in criminal prosecution under the Computer Fraud and Abuse Act of 1986.
Do not discuss, enter, transfer, process, or transmit classified and/or sensitive national security information of greater sensitivity than that for which this system is authorized. Use of this system constitutes consent to security testing and monitoring. Unauthorized attempts to upload information or change information on this service are strictly prohibited and may be punishable under the Computer Fraud and Abuse Act of 1986 and the National Information Infrastructure Protection Act.