About 20 years ago, an itinerate inventor named Maurice Ward demonstrated a super insulating paint that he claimed would protect most anything from intense heat. He called it Starlite, and at first no one believed the claims. Then he demonstrated it on TV, see below, by painting a paper-thin layer on a raw egg. He then blasting the egg with a blow torch for a minute till the outside glowed yellow-red. He then lifted the egg with his hand; it was barely warm! And then, on TV, he broke the shell to show that the insides were totally raw, not only uncooked but completely unchanged, a completely raw egg. The documentary below shows the demonstration and describes what happened next (as of 10 years ago) including an even more impressive series of tests.

Intrigued, but skeptical, researchers at the US White Sands National Laboratory, our nuclear bomb test lab, asked for samples. Ward provided pieces of wood painted as before with a “paper thin” layer of Starlite. They subjected these to burning with an oxyacetylene torch, and to a simulated nuclear bomb blast. The nuclear fireball radiation was simulated by an intense laser at the site. Amazing as it sounds, the paint and the wood beneath emerging barely scorched. The painted wood was not damaged by the laser, nor by an oxyacetylene torch that could burn through 8 inches of steel in seconds.

The inventor wouldn’t say what the paint was made of, or what mechanism allowed it to do this, but clearly it had military and civilian uses. It seems it would have prevented the twin towers from collapsing, or would have greatly extended the time they stayed standing. Similarly, it would protect almost anything from a flame-thrower.

As for the ingredients, Ward said it was non-toxic, and that it contained mostly organic materials, plus borax and some silica or ceramic. According to his daughter, it was “edible”; they’d fed it to dogs and horses without adverse effects.

The White sands engineers speculate that the paint worked by combination of ablation and intumescence, controlled swelling. The surface, they surmised, formed a foam of char, pure carbon, that swelled to make tiny chambers. If these chambers are small enough, ≤10 nm or so, the mean free path of gas molecules will be severely reduced, reducing the potential for heat transfer. Even more insulting would be if the foam chambers were about 1 nm. Such chambers will be, essentially air free, and thus very insulating. For a more technical view of how molecule motion affects heat transfer rates, see my essay, here.

Sorry to say we don’t know how big the char chambers are, or if this is how the material works. Ward retained the samples and the formula, and didn’t allow close examination. Clearly, if it works by a char, the char layer is very thin, a few microns at most.

Because Maurice Ward never sold the formula or any of the paint in his lifetime, he made no money on the product. He kept closed muted about it, as he knew that, as soon as he patented, or sold, or let anyone know what was in the paint, there would be copycats, and patent violations, and leaks of any secret formula. Even in the US, many people and companies ignore patent rights, daring you to challenge them in court. And it’s worse in foreign countries where the government actively encourages violation. There are also legal ways around a patent: A copycat inventor looks for ways to get the same behavior from materials that are not covered in the patent. Ward could not get around these issues, so he never patented the formula or sold the rights. He revealed the formula only to some close family members, but that was it till May, 2020, when a US company, Thermashield, LLC, bought Ward’s lab equipment and notes. They now claim to make the original Starlite. Maybe they do. The product doesn’t seem quite as good. I’ve yet to see an item scorched as little as the sample above.

Many companies today are now selling versions of Starlite. The formulas are widely different, but all the paints are intumescent, and all the formulas are based on materials Ward would have had on hand, and on the recollections of the TV people and those at White Sands. I’ve bought one of these copycat products, not Thermashield, and tested it. It’s not half bad: thicker in consistency than the original, or as resistive.

There are home-made products too, with formulas on the internet and on YouTube. They are applied more like a spackle or a clay. Still, these products insulate remarkably well: a lot better than any normal insulator I’d seen.

If you’d like to try this as a science fair project, among the formulas you can try; a mix of glue, baking soda, borax, and sugar, with some water. Some versions use sodium silicate too. The Thermoshield folks say that this isn’t the formula, that there is no PVA glue or baking soda in their product. Still it works.

Robert Buxbaum, March 13, 2022. Despite my complaints about the US patent system, it’s far better than in any other country I’ve explored. In most countries, patents are granted only as an income stream for the government, and inventors are considered villains: folks who withhold the fruits of their brains for unearned money. Horrible.