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The  (O Porriño, Spain) announces a milestone achieved in the 3D manufacture of a cryogenic tank demonstrator as part of the OVERLEAF project. The project, led by Spanish aeronautics company Aciturri, seeks to develop future liquid hydrogen (LH₂) storage tanks for future aircraft (learn more about the project’s innovations).

The designed solution consists of a dual system: an inner tank made of thermoplastic, responsible for maintaining LH₂ at extreme temperatures, and an outer carbon fiber structure that provides strength and structural safety. Aimen was responsible for manufacturing the inner tank, using high-precision, large-format additive manufacturing (AM).

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“This is a technological solution that will mark a before and after in the manufacturing of components for sustainable aviation,” explains Pablo Romero, team leader of the Additive Manufacturing of Composites R&D group and coordinator of the OVERLEAF project at Aimen. “We have applied all of our knowledge in robotics, AM and process design to address a highly technical challenge.”

The 1.5-meter-diameter tank was manufactured in a robotic cell developed by Aimen, equipped with high-performance 3D printing systems and infrared heating systems to ensure proper adhesion between layers. The process required more than 100 uninterrupted hours of printing and was monitored in real time using thermal cameras.

In addition to its technological contribution, Aimen has worked with the French center Canoe to develop a new sustainable material, based on a bio-based thermoplastic reinforced with natural fibers, which enables the printing of strong, lightweight and environmentally friendly structures.

“This project demonstrates how technology can respond to the major challenges of decarbonization. Investing in hydrogen as an energy vector also means transforming the systems that make it viable, and Aimen has a lot to contribute to this,” adds Xabier Pérez, researcher in the Additive Manufacturing of Composites R&D group and head of the tank’s additive manufacturing activities at Aimen.