TACOMA-OS

Sustainable lightweight moulds for next-generation hydrogen tanks

TACOMA-OS is a research and development project as part of the LuFo VI-3 aviation research programme led by AIRBUS in collaboration with other partners. The aim is to develop a new generation of sustainable, modular lightweight moulds for the production of CFRP liquid hydrogen tanks (LH₂).

The focus is on high-precision metallic moulding tools that enable economical, scalable and resource-efficient series production of cryogenic tanks - from the early concept phase through to industrial application.

Project goals

- Significant reduction in mould mass (≥ 30 %) compared to current reference solutions
- Modular mould concept for variable tank geometries (cone, cylinder, coupling segments)
- Reliable compliance with critical requirements for tightness, tolerances and surface quality
- Holistically sustainable design of tool design, production and utilisation
- Series production capability for future hydrogen aircraft and transferability to other industries

Technological approach

TACOMA-OS is based on the systematic combination of:
- modular tool architectures,
- iterative lightweight construction and structural optimisation,
- virtual design and process analysis,
- resource- and energy-efficient production strategies

Experience from aviation, wind and industrial mould construction is already incorporated into the requirements definition. This results in a robust tool specification that integrates and safeguards the design, choice of materials, interfaces and production logic.

Realisation and validation

In the project, a modular mould set is designed, manufactured and validated. This serves as an industry-relevant reference platform for the evaluation of:
- Scalability and modularity of the tools
- Interactions between mould design and tank production
- Energy, material and cost efficiency in the overall process

The knowledge gained flows into design guidelines, manufacturing instructions and sustainable tool specifications for series application.

Added value and impact

- Key technology for hydrogen aviation
- Reduced manufacturing costs for CFRP LH₂ tanks
- Significant savings in material and process energy
- Increased industrialisation and series production capability
- Strengthening Ostseestaal's technological leadership in sustainable mould making

Extract from the project key figures

- Funding programme: LuFo VI-3
- Duration: 07/2023 - 09/2026
- Application: CFRP liquid hydrogen tanks
- Focus: modular, sustainable lightweight moulds