Modeling, fabrication, and burst testing of type-IV 3D printed plastic liner composite overwrapped pressure vessels

Composite overwrapped pressure vessels (COPVs) are prominent components in aerospace propulsion systems, renowned for their exceptional strength-to-weight ratio, resilience under extreme pressure and temperature conditions, and significant weight reduction benefits for spacecraft and rockets. This paper focuses on the utilization of plastic liners within COPVs, constructed from materials Polyamide (Nylon) and Acrylonitrile Butadiene Styrene due to their superior strength-to-weight properties. Plastic liners are 3D printed as single components using fused deposition modelling. Subsequently, the COPV manufacturing process employs filament winding, with E-Glass Fiber reinforcement, and epoxy resin impregnation, followed by curing under high pressure. Testing procedures involving pneumatic and cyclic loading assessments are conducted, validated with finite element analysis solutions. Results highlighting the critical pressure threshold at which potential failures occur.