Scientists have created a new 3D-printed mold that dissolved in water to produce linerless, lightweight tanks for storying hydrogen in addition to other gases under high pressure.
The mold, also known as mandrel, was designed by a group of researchers at the Department of Energy’s (DOE) Oak Ridge National Laboratory (ORNL). As part of the project, the team worked together with aerospace firm Infinite Composites, additive manufacturing company JuggerBot 3D, and Oklahoma State University.
Ahmed Arabi Hassen, PhD, who led the project, revealed that the technology uses a specially tailored water-soluble polymer to create the mandrels. These are then used to manufacture Type V composite pressure vessels.
These vessels are entirely made from composite materials. They also do not need a permanent internal liner. On top of that, they can store hydrogen, compressed natural gas, nitrogen, and helium for the aerospace, defense, transportation, and energy industries.
A water-soluble mandrel
Lightweight gas storage tanks can be difficult to produce especially when creating and removing the internal molds used to shape them. Engineers rely on expensive metal molds or complex tools that must be disassembled before removal.
Hassen discussed the significance of Type V composite pressure vessels, and their potential. “Type V linerless compositepressure vesselsrepresent the next frontier in lightweight, high-pressure gas storage, but their manufacturing remains extremely challenging, particularly when it comes to producing and removing complex internal tooling,” he added.
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To tackle the challenge and create a temporary mandrel, the researchers turned to large-format additive manufacturing, commonly known as3D printing. They used a specially formulated polymer that can dissolve in water, which serves to print the mold in the desired shape of the tank.
The engineers then wound carbon fiber around the mandrel to create the vessel’s outer structure. Once thecomposite materialcured, they dissolved the temporary mold in water. As a result, the team designed a hollow carbon-fiber tank without a permanent internal liner. They then applied a gas-barrier coating to the vessel.
Making gas tanks lighter
The research team pointed out that the technology does not require complicated mechanical systems to remove the internal tooling. It can also eliminate the need forsolventsduring mold removal, and simplify the production of large pressure vessels.
Hassen explained that the method could also ensure high dimensional accuracy. “Our water-soluble, 3D-printed mandrels represent an important step toward overcoming this barrier and enabling scalable, cost-effective manufacturing of Type V vessels,” he continued.
The design also reduces the tanks’ overall weight and prevents problems caused by permanent internal liners. Additionally, replacing conventional metal tooling with 3D-printed molds could cut manufacturing complexity, shorten production times, and lower costs.
This could be useful for industries that require lightweight gas storage systems capable of operating under high pressure. “This achievement demonstrates how advanced manufacturing and strong industry partnerships can help bring these technologies closer to commercial reality,” Hassen concluded in apress release.
The team carried out its research at the Department of Energy’s Manufacturing Demonstration Facility. The project was backed by theDOE’s Officeof Critical Minerals and Energy Innovation.
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Georgina JedikovskaBased in Skopje, North Macedonia. Her work has appeared in Daily Mail, Mirror, Daily Star, Yahoo, NationalWorld, Newsweek, Press Gazette and others. She covers stories on batteries, wind energy, sustainable shipping and new discoveries. When she's not chasing the next big science story, she's traveling, exploring new cultures, or enjoying good food with even better wine.
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Scientists have created a new 3D-printed mold that dissolved in water to produce linerless, lightweight tanks for storying hydrogen in addition to other gases under high pressure.
The mold, also known as mandrel, was designed by a group of researchers at the Department of Energy’s (DOE) Oak Ridge National Laboratory (ORNL). As part of the project, the team worked together with aerospace firm Infinite Composites, additive manufacturing company JuggerBot 3D, and Oklahoma State University.
Ahmed Arabi Hassen, PhD, who led the project, revealed that the technology uses a specially tailored water-soluble polymer to create the mandrels. These are then used to manufacture Type V composite pressure vessels.
These vessels are entirely made from composite materials. They also do not need a permanent internal liner. On top of that, they can store hydrogen, compressed natural gas, nitrogen, and helium for the aerospace, defense, transportation, and energy industries.
A water-soluble mandrel
Lightweight gas storage tanks can be difficult to produce especially when creating and removing the internal molds used to shape them. Engineers rely on expensive metal molds or complex tools that must be disassembled before removal.
Hassen discussed the significance of Type V composite pressure vessels, and their potential. “Type V linerless compositepressure vesselsrepresent the next frontier in lightweight, high-pressure gas storage, but their manufacturing remains extremely challenging, particularly when it comes to producing and removing complex internal tooling,” he added.
More from Innovation
See AllInnovationNew class of tough metals avoids cold-weather fractures, offers better materials for clean energyInnovationGeorgia Tech’s Nexus AI supercomputer can now be accessed by all US scientistsInnovationThinner platinum coating could cut metal use in hydrogen equipment by 88%InnovationOxygen-based chipmaking method controls 2D crystal growth with over 99% successInnovationTiny chip stores memories in flowing water without conventional electronicsCredit:Logan Korn / ORNL, U.S. Dept. of Energy
To tackle the challenge and create a temporary mandrel, the researchers turned to large-format additive manufacturing, commonly known as3D printing. They used a specially formulated polymer that can dissolve in water, which serves to print the mold in the desired shape of the tank.
The engineers then wound carbon fiber around the mandrel to create the vessel’s outer structure. Once thecomposite materialcured, they dissolved the temporary mold in water. As a result, the team designed a hollow carbon-fiber tank without a permanent internal liner. They then applied a gas-barrier coating to the vessel.
Making gas tanks lighter
The research team pointed out that the technology does not require complicated mechanical systems to remove the internal tooling. It can also eliminate the need forsolventsduring mold removal, and simplify the production of large pressure vessels.
Hassen explained that the method could also ensure high dimensional accuracy. “Our water-soluble, 3D-printed mandrels represent an important step toward overcoming this barrier and enabling scalable, cost-effective manufacturing of Type V vessels,” he continued.
The design also reduces the tanks’ overall weight and prevents problems caused by permanent internal liners. Additionally, replacing conventional metal tooling with 3D-printed molds could cut manufacturing complexity, shorten production times, and lower costs.
This could be useful for industries that require lightweight gas storage systems capable of operating under high pressure. “This achievement demonstrates how advanced manufacturing and strong industry partnerships can help bring these technologies closer to commercial reality,” Hassen concluded in apress release.
The team carried out its research at the Department of Energy’s Manufacturing Demonstration Facility. The project was backed by theDOE’s Officeof Critical Minerals and Energy Innovation.
Get the latest in engineering, tech, space & science - delivered daily to your inbox.
By subscribing, you agree to our
Terms of Useand
PoliciesYou may unsubscribe at any time.
0
COMMENT
Subscribe to
Today!
Access to exclusive content, expert insights and a deeper dive into engineering and tech. No ads, no limits.
Explore Now!By
Georgina JedikovskaBased in Skopje, North Macedonia. Her work has appeared in Daily Mail, Mirror, Daily Star, Yahoo, NationalWorld, Newsweek, Press Gazette and others. She covers stories on batteries, wind energy, sustainable shipping and new discoveries. When she's not chasing the next big science story, she's traveling, exploring new cultures, or enjoying good food with even better wine.
- 1US to get 46,000-square-foot new submarine repair center that can boost battle readiness
- 2New electric car battery concept promises lighter packs with improved driving range
- 3New floating nuclear power project secures 4.95% enriched uranium fuel for testing
- 4China proposes new submarine tank that could operate underwater for up to two hours
- 5X-ray imaging detects pores as small as 80 nanometers in nuclear fuel cladding
