Mel Composites (Barcelona, Spain) has reinforced its partnership with Técnico Solar Boat (Lisboa, Portugal) — a boat project comprising cross-degree engineering students from Instituto Superior Técnico in Portugal — through the successful hull infusion of the São Gabriel 01, an 8-meter-long, 2.4-meter-wide, hydrogen-powered hydrofoiling vessel.

Source | Mel Composites

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 through composites manufacturing combined with clean energy systems.

The collaboration has evolved over 3 years, with Mel Composites bringing its composite materials expertise and precision infusion technology to the forefront. The project’s 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,” says Eduardo Galofre, CEO, Mel Composites. “We worked closely with the team to engineer a structure capable of supporting a hydrofoiling hydrogen propulsion system, where every layer, every fiber and every resin flow had to perform flawlessly.”

To support the infusion process, Mel recommended and 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.
• Aircell high-performance PVC foam core materials selected for its 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,” says 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.”

The São Gabriel 01 represents a major step forward for Técnico Solar Boat, a fully hydrogen-powered prototype designed to fly above the water on foils, reducing drag and maximizing efficiency. The project embodies the team’s mission to accelerate sustainable innovation in marine mobility.