Application:

Hydrogen storage

The problem

Hydrogen storage for aerospace, automotive, marine, and defense applications demands maximum capacity with minimum weight.

Conventional high-pressure tanks are limited by:

  • Heavy wall construction that reduces gravimetric efficiency
  • Restrictive shapes that limit integration in tight spaces
  • Potential leakage under long-term high-pressure service
  • Complex manufacturing requiring multiple components and joints

For lightweight, high-capacity hydrogen storage, a new approach is needed.

Our solution: 

Ultima Forma’s composite over-wound vessel incorporates a continuous thin metal gas barrier to combine the weight efficiency of advanced composites with the permeability resistance of metal.

Our patented design delivers:

  • Integrated bosses for seamless connection to the system
  • Modular architecture for different capacities and configurations
  • Conformal design potential to fit within available space
  • Continuous barrier layer for ultra-low hydrogen permeability

Proven technical performance: 

  • Gravimetric efficiency >12% possible for a 720 L tank
  • 14% improvement in efficiency over typical composite designs
  • Hydrogen permeability: 2.5 × 10⁻¹⁷ mol/m²·s·Pa
  • Pressure tested to over 850 bar with proven containment performance

Why it is better:

  • More hydrogen per kilogram — extend range or endurance without adding weight
  • Ultra-low leakage rates — maintain fuel quality and safety
  • Customisable size and geometry — better integration into vehicles or vessels
  • Reduced system mass — enabling higher payload or better fuel economy
  • Proven in testing — ready for deployment in demanding environments

More Applications

Leading edge protection

Waveguides