Putting next-gen materials, systems, and energy technologies to the ultimate test
Syensqo brings deep expertise in material science and engineering to support the goal of creating a fully hydrogen-powered aircraft capable of flying non-stop around the globe. Behind the mission is a team of expert minds who are designing, testing, and crafting a groundbreaking plan that pushes our technology and our imagination to new heights.
Hydrogen storage at -253°C
Storing liquid hydrogen at -253°C continuously for up to nine days is one of aviation’s most extreme challenges, and one of the greatest technical leaps Climate Impulse will take.
To make this possible, Syensqo is contributing advanced material science solutions across multiple layers of the hydrogen tank system. Our high-performance epoxy resins and carbon composite materials are engineered to endure extreme cryogenic temperatures while offering the toughness, damage tolerance, and fatigue resistance essential for long-haul endurance. These materials provide the structural integrity required under constant thermal stress, without the added weight of metal.
To maximize fuel efficiency, we’re targeting a gravimetric efficiency of around 50%, meaning the tank would carry as much hydrogen as the tank itself weighs, a key milestone for sustainable aviation range.
We’re also exploring advanced insulation systems using vacuum and multilayer insulation technologies. These solutions, enhanced by Syensqo’s composites, allow for high thermal efficiency without compromising structural performance. Combined, they create tanks that are lightweight, durable, and thermally optimized, opening the door for scalable, cryogenic hydrogen flight.
Learn more on Hydrogen Cryogenics
Fuel cell integration for continuous power
After hydrogen is stored, it must be transformed into flight-ready energy. That’s where our fuel cell technology comes in.
Fuel cells convert hydrogen and oxygen into electricity, cleanly and quietly, with only water as the byproduct. But doing this at scale, for nine days straight, demands materials that are ultra-efficient, heat-resistant, and extremely durable.
Syensqo supports this mission through a portfolio of high-performance materials developed within our Green Hydrogen Platform. Key enablers include:
- Aquivion® ionomer, which enable the fuel cell to reach efficiencies as high as 60%, thanks to their excellent conductivity and thermal stability — a critical feature for long-duration, high-temperature operation
- Advanced polymers such as Udel® PSU, Radel® PPSU, Amodel® PPA, Ryton® PPS, and Tecnoflon® FKM, which ensure durability, chemical resistance, and thermal reliability across the balance-of-plant
To further optimize design and reduce mass, Syensqo’s additive manufacturing capabilities allow us to produce complex, ultra-light components that traditional methods can’t match. Using materials like KetaSpire® carbon fiber PEEK, and PEI, we’re creating 3D-printed fuel cell parts with exceptional mechanical and thermal performance — all while cutting weight and enhancing integration.
This system is the clean engine of Climate Impulse — and a blueprint for zero-emission power beyond aviation.
Explore the science: Hydrogen Fuel Cells
Ultra-light composites for maximum efficiency
Flying around the world on hydrogen means using every gram of energy wisely, and that starts with building a lighter aircraft.
Syensqo’s aerospace-grade composites offer unmatched strength-to-weight efficiency, allowing the aircraft to remain ultra-light while withstanding turbulent weather, solar exposure, and long-duration stress.
We’re supplying:
- MTM®45-1, a benchmark carbon-fiber prepreg used across the aviation industry for its exceptional mechanical performance and thermal resistance
- Composite systems from the Cycom® family for structural stiffness and fatigue durability
- Structural adhesives like FusePly® and AeroPaste®, engineered for secure, efficient assembly
- SurfaceMaster™ surfacing films, enabling ultra-smooth finishes that minimize drag without added paint weight
These materials are used throughout the aircraft’s structure, including the fuselage, engine pods, pilot capsule, and more.
The result: a 600 kg weight reduction, enabling up to 3,500 kilometers of additional flight range. That’s a game-changing advantage for a mission crossing oceans on clean energy.
Optimizing performance with flight-informed AI
Efficiency isn’t only built into the aircraft’s materials, it’s built into how it flies. Syensqo, in collaboration with University Mohammed VI Polytechnic (UM6P) and Climate Impulse, is developing a cutting-edge AI-based decision support system that helps pilots fly more efficiently, like a glider navigating the wind.
This system uses physics-informed neural networks to analyze aerodynamics, weather patterns, and flight dynamics in real time. The AI acts as a virtual co-pilot, guiding the crew to:
- Detect and ride natural lift from rising air currents
- Adapt flight paths to optimize wind energy use
- Minimize hydrogen consumption while maximizing endurance
This is not just automation, it’s intelligence built on physical flight principles.
By reducing energy waste through smarter navigation, AI becomes a key enabler of the mission’s range and reliability. It’s a breakthrough that has applications well beyond this flight, laying the groundwork for a new era of smart, sustainable aviation.
Learn more: Digital & AI Innovation
