• • The stiff–soft synergistic assembly yields a compressive strength of 2.5 MPa, flexural strength of 6.25 MPa, and tensile strength of 40 MPa, enabling load-bearing applications where pure silica aerogels fail.
• • Viscosity-tunable PMSQ gel inks are precisely matched to hollow framework geometries via a modified Hagen–Poiseuille model, ensuring defect-free filling and consistent mechanical performance.
• • The strategy is versatile across diverse hollow structures (honeycomb, wheat straw, hollow fibers), demonstrating scalability for industrial thermal insulation panels and protective textiles.
• • The composites retain excellent thermal insulation properties, critical for energy-efficient building envelopes and cold-chain logistics, without compromising mechanical robustness.