Innovations in Cryogenic-Ready 3D Printing & Materials for the Liquid Hydrogen Storage Inner Tank

With its final webinar, the OVERLEAF project showcased its significant advances in cryogenic 3D printing and materials for the Inner Tank. This event presented revolutionary technologies and innovations developed by four expert partners, focused on creating high-performance components resistant to extreme cryogenic conditions.

CANOE, with Teddy Fournier, presented innovations in 3D printing filament production using thermoplastic-reinforced polymer compounds for cryogenic applications and the development of high-capacity “super spools” enabling continuous large-scale additive manufacturing. These special filaments, enriched with nanomaterials and carbon fibers, are designed to withstand extremely low liquid hydrogen temperatures while maintaining flexibility and mechanical strength, outperforming conventional materials that become brittle in cryogenic environments.

AIMEN, represented by Ander Reizabal, demonstrated large-format additive manufacturing (LFAM) strategies for producing full-scale hydrogen tanks, focusing on material optimization and advanced monitoring systems that ensure structural integrity. The LFAM process combines synchronized 6-axis robots and a rotating print bed to deposit material with precision and speed, enabling the rapid production of large components while significantly reducing time and costs. Real-time monitoring systems detect and automatically correct anomalies during printing, ensuring consistent quality and perfect layer adhesion to prevent hydrogen leakage.

University of Girona, with Jordi Renart, shared innovative approaches for testing 3D-printed materials at cryogenic temperatures, showing how specific formulations can maintain structural integrity even at -253°C, essential for LH2 tanks. Researchers developed a cryogenic test chamber simulating real-use conditions to evaluate critical parameters like fracture resistance, fatigue behavior, and hydrogen permeability, opening new possibilities for lighter and more compact tank designs.

ICSI, through Ionete Eusebiu Ilarian, presented technology for removing trapped gases from open-cell foams used as insulating materials, improving tank energy efficiency and reducing liquid hydrogen evaporation rates. The innovative process combines pressurization and depressurization cycles with inert fluids at controlled temperatures, reducing thermal conductivity by up to 40% and increasing material longevity in cryogenic conditions.

In case you missed the event, or you want to further explore the OVERLEAF advancements in the Inner Tank development, you can re-watch the full webinar through our YouTube channel by clicking below.

A big shootout to all the partners who contributed to this webinar series and to the innovative results the OVERLEAF project is achieving! This series concludes here, but research moves forward.

Photo credits: Chevanon via Freepik