ILCT – Innovative Laminate Solution for Cryogenic Tanks

ILCT is a R&D project conducted by Coexpair in collaboration
with the European Space Agency (ESA) under the General Support Technology
Programme (GSTP). The project addresses one of the major technological
challenges for future space systems and hydrogen-based propulsion: the safe,
lightweight and cost-efficient storage of liquid hydrogen at cryogenic
temperatures. ILCT focuses on the development of linerless, composite-only
cryogenic tank shells (Type V), aiming to replace traditional metallic solutions
that impose significant mass penalties.

The objective of ILCT is to de-risk an innovative laminate
concept capable of acting simultaneously as a structural element and a hydrogen
barrier at -253 °C. By leveraging Coexpair’s proprietary SQRTM manufacturing
process, the project targets a substantial reduction in porosity (below 0.1%)
and a tightly controlled fiber volume fraction, both critical to limiting
microcrack initiation and hydrogen permeability under cryogenic cycling. A
generic 40-liter spherical tank was defined as a reference case to support
feasibility studies, structural sizing and manufacturing assessments. Coexpair
adopted a multi-concept approach, combining composite processing with advanced
material architectures (i.e., thin plies and embedded barrier features to
mitigate crack propagation). Permeability testing before and after cryogenic
cycling demonstrated leak rates significantly below ESA-defined requirements,
with the most advanced laminate concepts showing up to an order-of-magnitude
improvement over state-of-the-art solutions. Engineering analyses and
preliminary cost assessments confirmed the potential for mass reductions
exceeding 50% compared to metallic tanks, alongside recurring cost benefits
driven by composite processing.

ILCT successfully increased the TRL/MRL of composite
Type V hydrogen tanks, established a solid technical foundation for further
qualification and positioned Coexpair as a key contributor to Europe’s future
capabilities in cryogenic hydrogen storage for space launchers and beyond.