Design Optimization and Structural Evaluation of a Fully Composite Type V Hydrogen Tank for Use in Aviation

The growing demand for sustainable energy solutions in the aerospace industry, particularly in line with the Paris Agreement, has accelerated interest in hydrogen-based onboard fuel systems. This study focuses on the optimization and structural analysis of a lightweight and high-strength Type V composite pressure vessel designed for aviation applications and capable of storing gaseous hydrogen at an internal pressure of 700 bar.A filament-wound manufacturing approach was selected due to its favorable strength-to-weight characteristics. The optimization process was conducted using an integrated computational framework developed in MATLAB and ANSYS ACP, and a two-stage methodology was adopted. In the first stage, a prototype was manufactured based on initial optimization results, and a leakage test was performed. The test outcomes revealed certain deviations between the measured response and simulation predictions. These findings were then utilized as key inputs in the second stage, where the design space was redefined, a refined optimization study was conducted, and the fabrication of a second prototype was initiated. In both stages, Genetic Algorithms (GA) coupled with surrogate models were employed to efficiently explore the design space. Structural assessments were carried out using finite element analysis (FEA), incorporating the failure criterias to examine the mechanical integrity of the tank. This study aims to contribute to the development of high-performance and lightweight hydrogen storage solutions aligned with the sustainability objectives of the aerospace sector by presenting a systematic engineering approach that integrates manufacturing–testing–re-optimization cycles.