Green Altitude: Crossing the Alps with Hydrogen
CELLSIUS H2-Sling Takes Off: Lightweight, Silent, Emission-Free!
Taking Off into the Future – Emission-Free with Hydrogen!
Taking to the Skies with Hydrogen – The CELLSIUS Project H2 at ETH Zurich
Sustainable flight above the clouds – that’s the vision driving students as they develop a hydrogen-powered aircraft. At its heart: a high-performance 100 kW fuel cell system delivering fully emission-free propulsion. The aircraft operates on 5.2 kg of hydrogen compressed to 700 bar. Combined with the specially developed electric drive, this system ensures efficient energy supply to the plane. To minimize weight, our RAKU® TOOL board materials are used to manufacture innovative lightweight components.
The result? An aircraft that sets new standards – both technically and environmentally.
The goal? By summer 2026, the first emission-free flight over the Alps is set to become a reality.
Application
Lightweight components manufactured using RAKU® TOOL WB-0700 and SB-0470 board materials.
Students at ETH Zurich are developing Switzerland’s first hydrogen-powered light aircraft as part of the CELLSIUS Project H2 – setting new benchmarks for sustainable aviation with cutting-edge fuel cell technology. To maximize efficiency, innovative lightweight components are key: RAKU® TOOL board materials are used to produce the molds for critical parts such as winglets, fairings, and engine cowlings.
Requirements for RAKU® TOOL Board Materials:
- Good temperature resistance
- Dimensional accuracy and stability
- Excellent machinability
- Closed, dense surface
- Chemical resistance
Manufacturing Process for Prepreg Lay-Up Tools
1. Bonding of WB-0700 boards using epoxy adhesive RAKU® TOOL EP-2304 / EH-2934-1 to form a blank
2. Machining on a 5-axis CNC according to CAD data (contour and geometry)
3. Surface finishing: fine sanding and sealing of the surface
4. Application of release agent
5. Lay-up of prepregs
6. Temperature cycle in the autoclave / final inspection
Manufacturing Process – SB-0470 Master Model to Produce a Prepreg Mold
1. Bonding of board material using RAKU® TOOL EP-2305 / EH-2904-1
2. Machining on a 5-axis CNC according to CAD data (contour and geometry)
3. Sanding and sealing of the mold surface (pore sealing), followed by application of release agent
4. Application of gelcoat (RAKU® TOOL EG-2105 / EH-2950-1)
5. Resin infusion process with glass fiber fabrics (RAKU® TOOL EI-2500 / EH-2971)
6. Stepwise curing in an oven to achieve maximum temperature resistance
7. Finishing of the prepreg lay-up mold
8. Release agent pretreatment
9. Lay-up of prepregs
10. Temperature cycle in the autoclave / final inspection
