A novel processing route for developing microporous insulation materials with layered structure has been developed. In this study, microporous insulation materials with layered structure were fabricated by controlling template morphology and additive compositions. The microstructure, porosity, mechanical strength, and thermal conductivity of microporous insulation materials were characterized as functions of the forming pressure, ceramic composition, template content, and sintering time. By controlling the processing parameters, template type, template content, and additive composition, it was possible to adjust the porosity from 30% to 70%. Typically, compressive strength and thermal conductivity of microporous insulation materials with -55% porosity were ~14 MPa and 0.41 W/nrK, respectively.
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