A comprehensive review of hydrogen storage pressure vessels: Materials, fabrication, performance, testing procedures, and modelling approaches

The global transition toward sustainable energy has positioned hydrogen as an alternative to fossil fuels. However, its efficient storage remains a significant challenge. High Pressure Gaseous Hydrogen (HPGH₂) storage is currently the most viable solution for safe and efficient hydrogen storage in both transportation and stationary applications. This review article provides a comprehensive analysis of the design, manufacturing, and the performance of hydrogen storage vessels. It compares Type I–V vessels, highlighting the shift from heavy all metal constructions towards light weight COPVs and more recently, liner-less Type V designs. The review discusses manufacturing parameters, material selection, geometry, and their impact on key performance metrics such as burst pressure and fatigue resistance. The study also integrates findings from recent experimental testing and Finite Element Analysis (FEA) to provide insights into failure predictions and safety margins. Finally, a structured design decision flow chart is proposed offering a systematic framework for the design of hydrogen storage pressure vessels. The work aims to identify critical research needs in sustainable materials, optimized manufacturing, and improved predictive tools to support the development of lightweight, safe, and cost-effective hydrogen storage vessels.