MEL Composites ramps up production and builds the hull of a hydrogen vessel

Técnico Solar Boat’s São Gabriel 01 is an 8m long and 2.4m wide hydrogen-powered hydrofoiling vessel designed to compete at the Monaco Energy Boat Challenge in July 2026. The construction of the hull required an optimal balance between lightness, stiffness and hydrodynamic performance. MEL Composites designed a structure capable of supporting a hydrogen-powered hydrofoil propulsion system. These requirements necessitated a customised infusion process and a fully integrated composite materials solution tailored to the boat’s performance requirements.

Specifically, MEL Composites provided Técnico Solar Boat with:

• Sicomin InfuGreen 810 epoxy resin – a bio-based, DNV-GL approved marine-grade formulation optimised for vacuum infusion processes. This low-viscosity resin enables precise wet-out and is ideal for complex laminate structures.
• Aircell high performance PVC foam core materials selected for excellent compression resistance and low density, ensuring high stiffness to weight ratios in sandwich construction – a key factor in the performance of hydrofoils and hulls.
• Complete range of vacuum infusion consumables including vacuum bags, sealant tapes, tubing, fittings, breather and peel ply fabrics, ensuring consistent infusion, traceability and simplified procurement.

“MEL Composites has been a key partner in transforming this ambitious concept into reality,” said Joao Simao, Team Leader, Técnico Solar Boat. “Their experience and precision engineering enabled us to build a hull that’s not only lightweight but capable of withstanding the forces generated during hydrofoiling – a crucial step as we move toward international competition next year.”

Expansion plans for 2026

In response to the growing demand for custom core kitting and advanced foam engineering across all sectors (marine, industrial, wind energy and sporting goods applications), MEL Composites is preparing to ramp up production. For 2026, it has made significant investments, in particular the addition of new machinery and the extension of production space by more than 800 m².

MEL Composites will be present at JEC World 2026, in Hall 5, booth P21.

Cover photo: MEL Composites delivers advanced hull infusion for Técnico Solar Boat (source: MEL Composites)