Riding the waves of innovation
How CorPower Ocean harnesses the energy of the oceans – with support from Hennecke technology
The energy transition demands reliable solutions—especially where wind and solar reach their limits. Wave energy is considered one of the most consistent renewable energy sources worldwide. With its high energy density and predictable generation profile, it has the potential to complement other renewables effectively, making power supply more independent and stable.
Swedish company CorPower Ocean has taken on this challenge with an innovative concept for converting wave motion into electricity. Supporting this effort is the Hennecke GROUP, whose polyurethane technology plays a key role in the industrialized and scalable production of the floating high-tech energy converters.
CorPower Ocean – a systematic approach to wave power
Since 2012, CorPower Ocean has been developing highly efficient wave energy converters (WECs) that transform the constant motion of the ocean into clean electricity. Over the past decade, the technology has been refined through extensive R&D and testing programs. Today, the company operates a fully functional pilot plant off the coast of northern Portugal using its C4 WEC model.
Wave energy is stable and predictable. While not enough on its own, it plays a crucial role in a resilient energy mix when combined with intermittent renewables like solar and wind. CorPower Ocean aims to accelerate the global shift to 100% renewable energy, enhance energy security, and reduce CO2 emissions. In addition to its headquarters in Stockholm, Sweden, the company runs a composites competence center in Viana do Castelo, Portugal, where preparations are underway for the world’s first commercial 10 MW wave energy project.
The CorPower Ocean Wave Energy Converter
At the heart of CorPower’s technology lies its patented wave energy converter. Resembling a buoy tethered to the seabed, the device rises and falls with passing waves. Inside, advanced mechanical systems convert this oscillating motion into rotational energy, driving two generators to produce electricity.
A standout feature is the “Wave Spring” technology, which allows the system to resonate with incoming waves. This resonance boosts energy capture while minimizing the size and weight of the structure. The WECs can also detune themselves during extreme weather, reducing mechanical stress and significantly increasing durability in harsh marine environments.
Challenge: A robust and lightweight hull
Wave energy converters must be both efficient and resilient – capable of withstanding years of exposure to saltwater, UV radiation, and wave pressure. At the same time, they need to be as lightweight as possible to simplify transport, installation, and operation.
CorPower Ocean relies on a sandwich-structured hull made from advanced composite materials. In Viana do Castelo, the company has established a mobile factory concept that enables on-site production of buoy hulls – cutting logistics costs, reducing CO2 emissions, and shortening lead times.
The hull, measuring 9 meters in diameter and covering around 270 square meters, is manufactured within 48 hours using an innovative variant of the PUR-CSM coating technology co-developed with Hennecke.
High-performance coating application – powered by Hennecke
The integration of Hennecke’s polyurethane technology marks a true innovation in CorPower Ocean’s manufacturing process. The PUR foam serves as the core material in the hull’s sandwich structure and offers key advantages:
- Lightweight strength: High stiffness-to-weight ratio
- Thermal insulation: Protects sensitive internal systems
- Production efficiency: Fast, precise application
- Automation: Integration of PUR high-pressure metering into the filament winding machine enables approx. 80% automated hull production
Together with Hennecke, CorPower Ocean has optimized the PUR coating process for this specific application – adjusting foam density, expansion, and curing to achieve ideal mechanical and thermal properties.
“Our solution meets all requirements for lightweight construction, buoyancy, thermal insulation, and mechanical durability – while ensuring high production efficiency,” says Dieter Müller, Sales Manager at Hennecke and project lead. “The collaboration with CorPower is a perfect example of how innovative engineering and sustainable manufacturing go hand in hand.”
From Lab to Series Production
The project began in early 2023 with tests at the Hennecke TECHCENTER. Initial prototypes were produced using a scale model and prepared for mechanical testing. Based on these results, a robust design was developed featuring a sandwich structure with a PUR core.
The biggest challenge was integrating the polyurethane metering system into the filament winding machine. Thanks to Hennecke’s technical expertise, a solution was developed that allows a single machine to handle the entire production process. The system was fully commissioned in May 2025 and is currently in the testing phase. “Working with Hennecke has been a real asset,” confirms Fabio Miguel, Composite Lead Engineer at CorPower Ocean. “The solution is perfectly tailored to our processes – efficient, reliable, and sustainable.”
By developing a scalable manufacturing concept and integrating cutting-edge PUR technology, CorPower Ocean is laying the foundation for the industrial use of wave energy – supported by Hennecke. A technology that is not only clean but also reliable, and thus a vital building block for tomorrow’s sustainable energy supply.
