This work investigates critical manufacturing challenges in Type IV composite hydrogen vessels (CPVs) through integrated computational and experimental analysis. Finite element analysis (FEA) conducted in Ansys Workbench optimized a 90°/±30°/±20°/90° filament-wound configuration with 20° isotensoid domes. The primary criterion was minimizing IRF—the ratio of applied load to ultimate composite strength—to below 1.0, with the chosen layup yielding 0.897 for optimal safety margin. This optimized configuration ensures safe operation at an internal pressure of 400 bar, negligible deformation of 0.944 mm, and a high natural frequency of 4200 Hz. However, experimental testing revealed premature failure via leakage below 10 bars due to three critical factors: material incompatibility under process loading, equipment scale mismatches, and process-induced defects from excessive fiber winding tension. While 3D-printed PLA liners demonstrated superior burst strength (25 bar) compared to blow-molded HDPE (15 bar) in isolated performance, stress-induced microcracking compromised system integrity. The results highlight a crucial divergence between computational predictions and as-built performance, demonstrating that manufacturability in emerging economies, i.e., resource-constrained manufacturing, depends critically on material-process compatibility, equipment adaptation, and workforce training in composite-specific quality assurance. These findings support strategic hydrogen infrastructure development by bridging the gap between advanced computational design and practical manufacturing realities. Future research should prioritize process-aware computational models incorporating manufacturing-induced stress states and equipment capability constraints rather than isolated design optimization, enabling more effective implementation of hydrogen storage technology in diverse industrial environments.
Reda et al. (Thu,) studied this question.