Nestled within the halls of Union College, a revolutionary startup — SunThru — is making strides in the world of sustainable and efficient window products. 

Founded by professor Mary Carroll of the Chemistry department and Ann Anderson of the Mechanical Engineering department, along with the touch of innovation at its core by fellow alumnus John Costa ‘17,  SunThru is on a quest to change how we perceive and utilize aerogel in our everyday lives. 

Aerogel, often referred to as a “block of solid air,” has a unique silica-based porous structure, which affords it low thermal conductivity. SunThru envisions embedding transparent blocks of this material into window products, specifically insulated glazing units (IGUs). By inserting aerogel between double pane windows, the efficiency of a triple pane window can be achieved, promising significant energy savings. With agencies like the EPA highlighting the monumental energy losses associated with inefficient windows, SunThru’s solution presents a timely and impactful answer. By replacing or upgrading windows with aerogel-embedded solutions, households and commercial properties could dramatically decrease their energy consumption, reducing both costs and greenhouse gas emissions.

Transitioning to more energy-efficient windows, such as triple pane models, is no easy feat. There are design modifications to consider, potential increased material costs, and even the hurdles faced by glazing contractors. However, SunThru’s proprietary aerogel solution bypasses many of these challenges. 

SunThru’s commitment to research, innovation, and fostering new talent has made it a hub for students with backgrounds in engineering and chemistry. The company offers an enriching environment where students can engage in meaningful projects, experiment with aerogel production, and even contribute to pioneering designs. 

“Our goal is to develop a hot press for large aerogel production, aiming to scale aerogel production from 5×5 inch to 20×14 inch aerogel. We’re hoping to get as many people involved as possible” – John Costa ‘17. 

Student workers will be helping with building SOMA-50 devices, running aerogel experiments and getting ownership in work and freedom to generate hypotheses and test them “I used to be a student myself as well” said John “I would love everyone to also have fun in the process”. There’s also the potential to work on innovative ventures like a methanol recapture system or operating a specialized press to produce large aerogels. Students from all majors are most welcome to join, especially those with a Chemistry or Engineering background.