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Starlite is an intumescent material that is claimed to be able to withstand and insulate from extreme heat. It was invented by British hairdresser and amateur chemist Maurice Ward (1933–2011) during the 1970s and 1980s, and received significant publicity after coverage of the material aired in 1990 on the BBC science and technology show Tomorrow's World. The name Starlite was coined by Ward's granddaughter Kimberly. The American company Thermashield, LLC, says it acquired the rights to Starlite in 2013 and replicated the material. Thermashield is the only company to have publicly demonstrated the technology and to have had samples tested by third parties, but subsequent investigations have concluded that the company's claims are unsubstantiated and that its evidence may have been faked.
Starlite reacts more efficiently as more heat is applied. The MOD's report, as published in Jane's International Defence Review 4/1993, speculated that this was due to particle scatter of an ablative layer, thereby increasing the reflective properties of the compound. Testing continues for thermal conductivity and Heat capacity under different conditions. Starlite may become contaminated with dust residue and so degrade with use. Keith Lewis, a retired MOD officer, noted that the material guards only against thermal damage and not the physical damage caused by an explosion, which can destroy the insulating layer.
Materials scientist Mark Miodownik has described Starlite as a type of intumescent paint, and one of the materials he would most like to see for himself. He has also admitted some doubt about the commercial potential of Starlite. Its main use appears to be as a flame retardant. Testing of modern composite materials enhanced with Starlite could expand the range of potential uses and applications of this substance.
The American company Thermashield, LLC, which owns the Starlite formula, stated in a radio interview that Starlite is not made from household ingredients and that there is no PVA glue or soda in it.
Thermashield's claims that Starlite has successfully passed femtosecond laser testing at the Georgia Tech and ASTM D635-15 Standard Testing.
NASA became involved in Starlite in 1994, and NASA engineer Rosendo 'Rudy' Naranjo talked about its potential in a Dateline NBC report. The Dateline reporter opined that Starlite could perhaps help with the fragile Space Shuttle heat shield. Naranjo said of their discussions with Ward, "We have done a lot of evaluation and... we know all the tremendous possibilities that this material has."
Boeing, which was the main contractor for the Space Shuttles in 1994, became interested in the potential of Starlite to eliminate flammable materials in their jets.
By the time of Ward's death in 2011 there appears to have been no commercialisation of Starlite, and the formulation of the material had not been released to the public.
Several experiments testing the replication and variant recipes showed that they could handle lasers, thermite, and torches, but the replication recipe failed when it was used to make a crucible for an induction furnace.
A FOIA request submitted to NASA to clarify its alleged endorsement received the following response: 'A thorough search was conducted... and no emails from Rosendo “Rudy” Naranjo, produced during the requested timeframe (1993–2001) or any other period, were located.'
The Aurora Press also uncovered evidence that the documentation that had been presented by Ward and others had been demonstrably falsified.
The investigation found that claims of NATO's involvement in testing Starlite at White Sands Missile Range were contradicted by official records, specifically through a FOIA request submitted to the United States Department of Defense. The request sought "all reports, memos, and/or email records relevant to the June 1991 testing of Starlite at White Sands Missile Range, a simulated nuclear blast test conducted in partnership with the United Kingdom's Special Air Service (SAS)". The United States Department of Defense responded, stating that they had "completed a search of documents and found no records".
The investigation also examined the alleged endorsement and testing by the Royal Signals and Radar Establishment (RSRE); this claim was disproved by the fact that had RSRE ceased to exist before the alleged tests took place.
Lastly, the investigation found that the Atomic Weapons Establishment (AWE) categorically denied conducting any tests on Starlite or holding relevant information. In a FOIA request, they stated: "...we can confirm that the Atomic Weapons Establishment (AWE) did not carry out any tests on the material... and does not hold any relevant information."
The company faced scrutiny over its claim that Starlite was tested at a "prestigious U.S. research institution." Attempts to verify this claim were met with vague responses, and no official confirmation was provided.
Additionally, the company cited testimonials from individuals and organizations, including Rudy Naranjo and the Sierra Nevada Corporation, but these claims were either contradicted by public records or lacked corroboration. Notably, the alleged correspondence with Naranjo was deemed implausible due to linguistic inconsistencies and his advanced Parkinson's disease at the time.
Furthermore, Thermashield's reliance on anecdotal evidence and the absence of peer-reviewed data after over a decade of operation have cast doubt on the company's credibility. The investigation concluded that many of Thermashield's claims remain incongruous and unsubstantiated.
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