Certification Roadmap to Yield an Optimal and Safety methodology of crashworthiness for an integrated cryogenic Tank for liquid hydrogen storAge on board of future aiRcraft

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Hydrogen is emerging as one of the most promising energy carriers for decarbonizing aviation, offering significant long-term potential for reducing greenhouse gas emissions. However, its implementation faces considerable technical and safety hurdles, particularly in relation to onboard storage and distribution. Hydrogen’s low volumetric energy density, even when stored as cryogenic liquid hydrogen (LH2), implies a need for tanks that are approximately four times larger than those used for conventional aviation fuels. This directly affects aircraft architecture, aerodynamic efficiency, and payload capability. Additionally, LH2 must be maintained at extremely low temperatures—around -253°C—which requires complex, highly insulated, and costly cryogenic tank systems. Hydrogen’s flammability and its capacity to permeate materials that are otherwise impermeable to conventional gases introduce further safety risks and demand stringent engineering countermeasures. The CRYOSTAR project confronts these challenges through the development of a pioneering crash certification methodology for cryogenic hydrogen tanks integrated into the tail section of CS-25 class aircraft. The project’s objective is to engineer, validate, and certify advanced attachment and restraint systems capable of absorbing crash loads while ensuring structural integrity and fuel containment. A comprehensive methodology—combining numerical modeling, physical testing, and credibility assurance frameworks—will support regulatory compliance while reducing development and certification costs. The project aims to define a future certification reference in collaboration with aviation regulators such as EASA, FAA, CAA. CRYOSTAR will achieve Certification Readiness Level (CRL) 5, targeting CRL 6 with flight validation, and Technology Readiness Level (TRL) 5 via full-scale drop tests on equipped fuselage sections, thus laying the foundation for safe and certifiable hydrogen-powered aviation.