Innovative Type-5 LNG Tank: Thermoplastic in-situ AFP Technology for Cryogenic Fuel Storage

As part of a research project funded by the European Space Agency (ESA), we developed an innovative Type-5 LNG tank at our site in Augsburg, together with Omnidea-RTG. The result marks a significant step toward lightweight, high-strength, and industrially scalable storage systems for cryogenic fuels such as hydrogen and methane in the aerospace sector.

End-to-End Development Chain: From Design to Joint Characterization

The complete development chain of this project covers all relevant steps:

• Structural design of the tank system
• Material selection: use of the high-performance thermoplastic CF/LM-PAEK (carbon fiber-reinforced low-melt PAEK)
• Permeability analyses to ensure leak-tightness under cryogenic conditions
• Mechanical characterization of the joints

Innovative Manufacturing Concept: Thermoplastic In-Situ AFP Process

A key innovation of the project is the development of a holistic manufacturing and tooling concept that enables the automated production of the entire tank structure using the thermoplastic in-situ AFP process (Automated Fiber Placement).

Notably, both the manufacturing of the two tank halves and their joining were carried out using the same manufacturing technology. This allowed the entire tank structure to be produced in a single, continuous process chain – without any additional assembly or joining techniques.

Advantages for Industrialization

This integrated manufacturing approach offers significant benefits for industrial scale-up:

• Reduced production costs by eliminating separate joining processes and special molds
• Lower complexity of production facilities
• Optimized utilization of manufacturing infrastructure

The Demonstrator: 1-Meter Diameter, Full Industrial Maturity