Aerogels are a class of advanced materials that have been of large interest to researchers due to their exceptionally porous structures, which provide high surface area and low density. These characteristics make them suitable for diverse applications, including thermal insulation, adsorption, and separation technologies. Polystyrene (PS), a widely available and intrinsically hydrophobic polymer, offers distinct advantages for aerogel fabrication, especially in environments requiring moisture resistance and structural durability. In this study, we developed a novel shear-driven liquid fabrication process to produce PS nanosheets (NSs), which act as the core structural units for aerogel formation. The PS NSs were synthesized using the process of antisolvent precipitation under liquid shear, introduced by the Velev group, where high-shear flows enabled efficient conversion of the PS solution into ultrathin nanosheets. The NS morphologies were characterized via optical and electron microscopy, confirming uniform nanoscale dimensions. To evaluate their suitability for aerogel construction, the PS NSs were foamed using either surfactants or water, followed by controlled drying. The resulting aerogels exhibited excellent hydrophobicity and ultralight density, retaining their structure without collapse. Notably, these aerogels are produced in a scalable process without freeze-drying, which makes them of large potential value. These PS NS-based aerogels show strong potential for environmental applications, particularly in oil-water separation and hydrophobic filtration, and represent promising candidates for environmental remediation and energy saving technologies.
