From Design to Application: How Manufacturing Processes Impact Composite Hydrogen Storage Tank Performance?

ABSTRACT Hydrogen storage tanks are pivotal to the advancement of the hydrogen economy, serving as essential components for the safe, efficient, and high‐capacity storage and transport of hydrogen fuel. While many studies have focused on tank performance under operational conditions, a comprehensive understanding of how manufacturing processes influence their mechanical behavior, durability, and long‐term reliability remains limited in the current literature. This review aims to bridge that gap by systematically examining the impact of manufacturing parameters such as material selection, fiber winding techniques, resin systems, curing protocols, and quality control on the structural and functional performance of hydrogen storage tanks. Spanning the entire lifecycle from design to application, there are key factors that affect tank performance, such as fiber orientation, porosity, bonding quality, and thermal stresses. Therefore, failure modes are used to identify, describe, and analyze the different performance trade‐offs associated with various fabrication methods. By consolidating fragmented insights across the literature and highlighting underexplored aspects of tank manufacturing, this study provides a roadmap for optimizing production strategies. The findings contribute to the development of safer, more durable, and cost‐effective hydrogen storage solutions suited for transportation, renewable energy systems, and industrial applications.