Spain's MEL Composites delivers lightweight hull for Monaco Boat

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, 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 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 excellent 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,” said 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.

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ALCHEMPro News Desk (RM)