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Author: Gennadi Schadrin | Glaston

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With both energy-efficiency targets and building renovations on the rise, insulating glass units with ultra-thin middle panes are expanding what’s possible. Lighter, thinner, and smarter, these solutions open up new possibilities for both performance and sustainability. But is ultra-thin glass processing really possible? In this blog, we’ll briefly cover how advanced technologies are making it a reality.

"Insulating glass units (IGUs) play a critical role in reducing energy loss in buildings. Traditionally, better thermal performance has meant heavier and thicker windows – but not anymore. Thanks to recent advancements, ultra-thin middle panes as slim as 0.5 mm can now be used in triple-glazed IGUs. These lightweight panes help reduce the overall unit weight and thickness by up to 30% while maintaining high energy performance with low u-values."

Thin-glass IGUs offer clear benefits. Requiring less frame support, they are ideal for both new construction and window retrofits. Plus, their greater light transmission and lower embodied carbon support stricter sustainability goals.

Redefining IGU production for ultra-thin glass

However, ultra-thin glass is very fragile.  Because it can easily be damaged or break, traditional production methods with their thermal and mechanical stresses are entirely unsuitable for handling such glass. To overcome these challenges, the entire approach to IGU production had to be redefined – an achievement now realized with the new ULTRA TPS^® line.

Redesigning the glass transportation method and adjusting the process sequence make it possible to handle the fragile ultra-thin glass gently. Instead of applying spacers directly onto the delicate center pane, they are placed on the more robust outer panes. At the same time, switching to advanced air float conveyors avoids the bending and vibrations caused by conventional air cushion transportation.

"This thin-glass IGU production technology is already in serial production and ready to scale – bringing lighter, smarter glazing to modern buildings everywhere."

Want to go deeper?

Download the presentation below to discover how Glaston’s novel technology overcomes the challenges to ultra-thin IGU production.

Watch the video recording from GPD 2025 presentation: