Brazilian Startup Develops Towpreg Technology to Support Lightweight Hydrogen Storage

Updated on July 10, 2026 • 5 min read

A Brazilian startup is advancing domestic production of towpreg, a carbon fiber reinforcement material widely used in composite pressure vessels, aiming to strengthen the country’s supply chain for hydrogen storage and other high-performance composite applications.

Based in São José dos Campos, the company has developed a locally manufactured towpreg technology with support from FAPESP’s Innovative Research in Small Businesses (PIPE) program. According to information published by FAPESP, the technology is intended to reduce Brazil’s dependence on imported prepreg materials while supporting the manufacture of lightweight composite cylinders for compressed gases.

The development targets one of the key challenges facing the hydrogen economy: transporting compressed hydrogen safely and efficiently while minimizing the weight of storage systems.

Lightweight Composite Cylinders Could Improve Transport Efficiency

Traditional steel pressure vessels remain widely used for transporting industrial gases but add significant weight to road transport and are susceptible to corrosion in demanding operating environments.

The Brazilian project focuses on supplying towpreg for Type IV composite pressure vessels, which combine a polymer liner with a carbon fiber composite overwrap. According to project estimates, replacing conventional metallic cylinders with composite alternatives could reduce cylinder transport weight by approximately 20%, increase trailer payload capacity by 50%, and lower logistics costs per cubic meter of transported gas by as much as 45%.

Although these figures represent project estimates, they illustrate the operational advantages that lightweight composite pressure vessels can offer for hydrogen and compressed gas distribution.

Domestic Towpreg Addresses Supply Chain Challenges

Towpreg consists of continuous reinforcement fibers—typically carbon or glass fiber—pre-impregnated with resin before filament winding or automated composite manufacturing.

Until now, Brazilian manufacturers have relied largely on imported towpreg materials, creating logistical challenges due to transportation requirements and limited storage life.

Project coordinator and chemist Michelle Leali Costa explained that conventional imported materials typically require refrigerated storage at approximately -18°C. Customs delays or interruptions in cold-chain logistics can shorten shelf life or render materials unsuitable for production.

To reduce these risks, researchers developed an epoxy resin formulation designed to remain stable for at least 90 days without refrigeration. The project also included optimization of fiber impregnation processes and production of semi-industrial demonstration prototypes.

Hydrogen Storage Drives Composite Demand

The primary application for the domestically produced material is expected to be hydrogen storage.

Hydrogen presents unique engineering challenges because of its low molecular size and the high pressures typically required for storage and transportation. Composite Type IV cylinders are widely regarded as one of the leading solutions because they combine corrosion resistance with substantial weight savings compared with all-metal pressure vessels.

According to the research team, local manufacturing could reduce the cost of composite cylinders in Brazil by up to 40%, potentially improving competitiveness against traditional steel alternatives while strengthening the domestic hydrogen supply chain.

Beyond hydrogen storage, the technology is also being evaluated for applications in aerospace, defense, automotive components, orthopedic devices and industrial piping systems.

Local Material Production Supports Composite Manufacturing

Professor’s Analysis

Although hydrogen storage cylinders often receive attention as finished products, the availability of precursor materials such as towpreg is equally important for developing regional composite manufacturing capability.

Towpreg is a critical intermediate material for automated filament winding because it combines reinforcement fiber and resin in a controlled form that supports consistent processing and laminate quality. Establishing domestic production reduces dependence on imported materials while improving supply chain resilience and manufacturing flexibility.

Another notable aspect of the project is the development of a room-temperature-stable epoxy system. Extending storage life without refrigeration could simplify logistics, reduce transportation costs and improve material availability for manufacturers located far from international supply routes.

However, commercialization will depend not only on manufacturing capability but also on qualification, pressure vessel certification and compliance with hydrogen storage standards. As hydrogen infrastructure expands globally, certified composite materials and reliable production processes will remain essential for market adoption.

Certification Remains the Next Step

While the material technology addresses supply chain and manufacturing challenges, commercial deployment will require compliance with pressure vessel regulations and industry standards.

According to the project, Brazil currently applies established certification pathways for biomethane cylinders but has yet to introduce dedicated national standards for hydrogen pressure vessels. Until those frameworks are developed, manufacturers will need to rely on internationally recognized certification requirements.

For the composites industry, the project highlights the growing strategic importance of localized material production as countries seek to build domestic capabilities in advanced composite manufacturing and hydrogen infrastructure.

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