Manufacturability‐Aware Multi‐Objective Screening of Filament‐Wound Type IV Pressure‐Vessel Cylindrical Sections Using Dual‐Pressure Hashin Constraints

ABSTRACT A manufacturability‐aware preliminary screening framework is proposed for the straight cylindrical section of filament‐wound Type IV composite pressure vessels. The method reduces the laminate design space before dome‐aware finite‐element and progressive‐damage analyses, rather than replacing full‐vessel burst assessment. Using the public DLR Type IV dataset, the overwrap is evaluated by Classical Lamination Theory under closed‐end membrane loading. Four helical angles and seven wound‐layer thicknesses are optimized with NSGA‐II under controller‐compatible angle and tow‐thickness quantization. The objectives are maximum hoop stress, maximum radial expansion, and cylindrical‐section mass. Feasibility is defined by a dual‐pressure, mode‐separated Hashin screen: fiber integrity is checked at a high‐pressure reference level, whereas matrix integrity is re‐evaluated at service pressure; Tsai–Wu is reported as a passive scalar indicator. For the nominal DLR layup, the model reproduces the experimental hoop strain–pressure slope within 3.8%, while underpredicting the axial slope by 16.5%. The representative knee design achieves , , and . Mass‐matched ablation and robustness studies show that selective hoop‐layer thickening is the dominant improvement mechanism, while the final compromise remains conditional on the prescribed design window.