Barcelona-headquartered MEL Composites has reinforced its partnership with Técnico Solar Boat through the successful hull infusion of the São Gabriel 01, an 8-metre-long hydrogen-powered hydrofoiling vessel. 

Designed to compete at the Monaco Energy Boat Challenge in July 2026, the São Gabriel 01 is the team’s most technically demanding project to date and showcases the future of sustainable marine engineering by combining advanced composite manufacturing with clean energy systems.

Building on a collaboration that has evolved over the past three years, MEL Composites brought its materials expertise and precision infusion technology to the forefront of the project. The hull – one of the most complex structures undertaken by Técnico Solar Boat –

required a tailored infusion process to achieve the optimal balance between lightness, stiffness and hydrodynamic performance.

“The São Gabriel 01 pushed the limits,” said Eduardo Galofre, CEO of Mel Composites. “We worked closely with the team to engineer a structure capable of supporting a hydrofoiling hydrogen propulsion system, where every layer, every fibre and every resin flow had to be flawless.”

To support the infusion process, MEL provided a fully integrated composites materials solution tailored to the vessel’s performance requirements. The bespoke package included Sicomin InfuGreen 810 epoxy resin – a bio-based, DNV-GL approved marine-grade formulation optimized for vacuum infusion processes. This low-viscosity resin enables precise wet-out and is ideal for complex laminate structures.  It was combined with Aircell high performance PVC foam core materials selected for excellent compression resistance and low density along with a range of vacuum infusion consumables including bags, sealant tapes, tubing, fittings and 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 at Técnico Solar Boat. “The company’s 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 towards international competition next year.”

www.melcomposites.es