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Hydrogen (H₂) pressure vessels are gaining critical importance as the mobility industry shifts toward sustainable energy solutions to combat climate change and reduce greenhouse gas emissions. With hydrogen offering a gravimetric energy density nearly three times greater than diesel or jet fuel, it has become a promising clean fuel alternative for transportation. However, its low volumetric energy density necessitates compression and safe, efficient storage—particularly in the form of high-pressure vessels for use in hydrogen-powered vehicles.

A major challenge in hydrogen storage is the weight of the pressure vessel, which significantly contributes to the overall system mass. This is especially critical in aerospace, automotive, and space applications, where lightweighting is essential for performance and fuel efficiency. To address this, pressure vessels are designed in five main types, ranging from fully metallic (Type I) to entirely composite structures (Type V). Among these, Type IV vessels—comprising a polymer liner overwrapped with composite materials—have become the standard in fuel cell electric vehicles due to their superior strength-to-weight ratio, high safety factor, and technological maturity.

Traditionally, filament winding (FW) has been the preferred method for overwrapping composite pressure vessels. While effective, FW has limitations including restricted fiber path flexibility, inability to make localized reinforcements, and compatibility only with symmetric geometries. These constraints hinder the optimization of structural performance and material efficiency.

To overcome these limitations, Automated Fibre Placement (AFP) is emerging as a superior alternative for manufacturing Composite Overwrapped Pressure Vessels (COPVs). AFP enables precise, programmable deposition of composite tows, supporting complex geometries, non-geodesic paths, and selective reinforcement. It reduces material waste, enhances design flexibility, and improves mechanical performance, making it an ideal technology for next-generation hydrogen storage solutions in high-performance mobility sectors.