About the project and its results

The manufacturing process of the tank may not be simple, but it is easily replicable, and even more so for minor-scale manufacturing. The main advantage of the process, however, is the flexibility: if additional ideas are to be incorporated, studied or tested, it is not only easy, but also much less expensive than other technologies.

Additive manufacturing much reduces material waste, especially when it involves components as big as the ones involved. This is because the amount of material is (roughly) the one used for the part itself, in contrast with the conventional subtractive manufacturing methods such as machining, which would require a raw material billet, most of which would be wasted.

A new generation of open cell foams are being developed. Thanks to their unique properties—lightweight structure, exceptional resistance to extremely low temperatures, and superior thermal insulation—these foams are expected to have a substantial impact. The supply chain will be impacted by new products and a new industrialisation process. This is focused on new markets that must be certified for the industry and for several sectors such as: Automotive, Aerospace, and Chemical and Environmental Industry.

The development of advanced foams can have a significant economic and market impact depending on their properties, applications, and competitive advantages. In OVERLEAF project freeze-dried nanocellulose foams are reinforced with silica for cryogenic insulation in liquid hydrogen storage. These materials offer superior thermal insulation, reducing boil-off losses and lowering storage and transportation costs. Their lightweight structure contributes to improved fuel efficiency in hydrogen-powered vehicles and aerospace applications. With the growing hydrogen economy, demand for high-performance insulation materials is rising, creating opportunities for innovative solutions. Companies investing in these technologies can gain a competitive edge in the emerging clean energy market.

The polyamide 11 Rilsan® used as thermoplastic matrix, is being sourced from castor plants which makes it ecofriendly. The outer tank, manufactured using carbon fibre PA11 thermoplastic tapes, can be easily recycled at the end of life and the composite design aims to maximise the gravimetric density.

The relatively low cost and availability of CO2 make the process economically viable, offering a competitive advantage over traditional foaming methods. Furthermore, the ability to fine-tune process parameters makes s-CO2 extrusion highly adaptable to a range of other applications.

Unlike traditional chemical blowing agents, CO2 is non-toxic, non-flammable and can be recycled throughout the process, reducing the environmental footprint. The use of CO2 in its supercritical state allows for precise control over foam characteristics, such as cell size, density, and mechanical properties, offering a versatile and cost-effective method for producing polymer foams.

The thermal insulation process is especially beneficial in industries such as aerospace, where high-performance materials are required for insulation and structural applications; automotive, for lightweight, durable components; energy, particularly for energy-efficient storage solutions and thermal insulation; and packaging, where sustainable and highquality foams can reduce material use.

These sensors offer exceptional versatility and can be seamlessly integrated into various hydrogen-dependent industries, including hydrogen-powered aviation, energy storage and industrial gas infrastructure.

As the global demand for hydrogen technologies accelerates, the need for reliable and high-performance hydrogen sensors will grow significantly. This positions the technology as a critical enabler for the safe and sustainable adoption of hydrogen across the transport and energy sectors, ultimately contributing to a cleaner, zero-emission future.

The sensors’ compact design, low power consumption, and scalability make them ideal for large-scale deployment, providing a cost-effective solution for real-time leak detection. Additionally, the spark-free operation enhances their safety profile, ensuring reliable monitoring in environments where conventional electrical sensors would pose a risk of ignition.

The ability to manufacture these sensors using existing fabrication techniques, such as magnetron sputtering (a commercially available method for depositing thin films) and commercial fibre optic fabrication techniques, further boosts their replicability and mass production potential, driving down costs and facilitating widespread implementation.