Advances in 3D Printing: Additively Manufactured Cryogenic Hydrogen Fuel Tank for Airplanes

AIMEN, a European research organization, has achieved a breakthrough in industrial innovation by building the first 3D-printed cryogenic fuel tank capable of storing liquid hydrogen at temperatures as low as -250 ℃. This development is a part of the European OVERLEAF project, which is headed by the Spanish aerospace firm ACITURRI and aims to create lighter and more effective technologies for the future of clean aviation.

AIMEN is a non-profit private association that was founded in 1967, with its headquarters located in Spain. AIMEN is globally recognized for its research in advanced manufacturing and material processing. 

How was the fuel tank developed?

The tank was created via large-format, high-precision additive manufacturing in a robotic 3D printing cell with multi-axis robotic arms and equipped with an infrared heating system to ensure proper adhesion between the layers and eliminate the phenomenon of warpage. Thermal cameras were employed to observe the process in real-time, maintaining quality control throughout the build time. The tank was continuously printed for over 100 hours, depicting both endurance and precision. The diameter of the tank was 1.5 meters, showcasing it as a suitable prototype for aerospace applications. 

Materials used for developing fuel tank

The designed tank consists of a dual material system: an inner tank made up of high-performance bio-based Polyamide 11 (PA11) reinforced with natural fibers, which can withstand extremely low temperatures, showcasing thermal resistance while being lightweight, and an outer tank consisting of carbon fiber-reinforced polymer, which provides the necessary mechanical strength to support structural loads under cryogenic conditions. Although which natural fiber was used remains unknown. 

3D printed cryogenic tank (Source: AIMEN)

This is a technological solution that will mark a before and after in the manufacturing of components for sustainable aviation. We have applied all our knowledge in robotics, additive manufacturing, and process design to address a highly technical challenge." says Pablo Romero, team leader of the 3D printing of Composites R&D group and coordinator of the OVERLEAF project at AIMEN.

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