HYMOCA

Inspiration

The HYMOCA project aims to develop a next-generation smart COPV with an optimized, damage-tolerant design guided by advanced in-house modelling tools and software. The doped resin matrix will enhance mechanical performance and reduce weight, while the integration of hybrid sensing systems (self-sensing and SMA-based) will ensure safer and more reliable operation.
For nanomaterials, HYMOCA leverages patented LIST technologies for nanoparticle functionalization. Silica nanoparticles will be surface-modified, and graphene nanoplatelets will be treated using soft-chemistry methods that preserve their crystallinity. This scalable approach enables control over catalyst and nanotube morphology and has proven effective in producing conductive polymer composites.
In terms of sensing and SHM, HYMOCA will embed graphene nanoplatelet percolation networks within the polymer matrix to create high-sensitivity strain gauges directly integrated into the vessel wall. Complementary SMA sensors developed by FRAUNHOFER will enhance strain measurement accuracy on elastic materials, outperforming traditional FOS and strain gauges. By combining self-sensing functionality with SMA-based strain monitoring, HYMOCA will deliver a comprehensive, multi-modal SHM system for real-time structural integrity assessment of composite pressure vessels.

Innovation

Exploring the opportunities for using nanoparticles to improve the properties of CFRP composites developed for COPVs is in its early stages. Moreover, Nanocomposites for Sensing and Structural Health Monitoring has not been yet introduced into COPV domain and is a real and ambitious goal of this project. Therefore, results obtained will provide a real industrial topic to be developed.

The innovation potential of the HYMOCA project can be summarized as follows:

• Improvement in durability by performance enhancement and damage prevention, potentially leading to weight and cost reduction,
• Enhancement in safety by facilitating the ease of maintenance and health monitoring, (no requirements and procedures for periodic re-qualification by inspection or testing during the service life).
• Development of new functionality of real-time self-sensing and structural health monitoring.

To achieve this, the project focuses on key areas of research and innovation:

• Research into advanced materials & composites: the project will demonstrate the effect of incorporating nanofillers into the composite: on one hand how these nanofillers will be used as sensors in the COPVs and in the other hand, the enhancements related to stiffness, interlaminar shear strength, and the fatigue behaviour of the vessel.
• New process: the integration process of the sensing systems, its stability, homogeneity, and feasibility on a large scale are big challenges that make the HYMOCA project more innovative.
• Cost reduction: this includes the saving in the carbon fibres induced by the new composite high performance (thanks to nanoparticles), the optimized design (thanks to advanced modelling and simulation), and lower safety factor (thanks to sensors).
• Safety abilities: a stronger material with real-time self-sensing structural health monitoring technology will prematurely detect any faults during functioning.

Impact

HYMOCA supports the decarbonization of transport, energy, and industry by developing smart, lightweight hydrogen pressure vessels with enhanced safety, durability, and reduced material use. Through advanced modelling, doped resins, and embedded sensing systems, the project enables longer service life, minimizes waste, and significantly lowers carbon emissions, directly contributing to European climate-neutrality objectives.

The project strengthens Europe’s industrial leadership by creating new opportunities across the hydrogen value chain, particularly in the automotive and mobility sectors. It promotes regional employment, technological independence, and competitiveness through the development of high-value manufacturing capabilities and advanced composite technologies.

HYMOCA advances European innovation excellence by combining nanomaterial functionalization, self-sensing composites, and multi-scale modelling into a unified design and monitoring framework. This integrated approach enhances predictive capabilities, material performance, and safety of hydrogen storage systems.

Scientifically, the project establishes a strong link between experimental and numerical investigations, leading to new design tools, manufacturing methods, and knowledge in functional and structural composites. It fosters skill development, open scientific dissemination, and international collaboration across academia and industry.

Economically, HYMOCA supports the growth of the European polymer and advanced composite sectors, while generating intellectual property, digital tools, and innovation pathways that reinforce Europe’s position in sustainable hydrogen technologies.