Process-structure-performance prediction of nanocomposite overwrapped pressure vessels: Manufacturing-driven design

This work presents a manufacturing-driven multiscale methodology for the design and structural assessment of filament-wound carbon fibre reinforced polymer (CFRP) composite overwrapped pressure vessels (COPVs) incorporating nano-modified epoxy matrices. The work integrates experimental characterization with predictive modelling in a unified framework. Neat epoxy resins were reinforced with nanosilica and graphene nanoplatelets (GNPs) using a controlled dispersion protocol. Composite plates were manufactured by filament winding and vacuum curing, then characterized by micro-computed tomography ( μ CT), tensile testing, and three-point bending to evaluate dispersion quality, void content, and mechanical behaviour. At the nanoscale, the effective elastic properties of the modified matrices were estimated using Mori–Tanaka homogenization, accounting for filler morphology and voids. These properties were introduced into a microscale finite element homogenization to determine orthotropic lamina properties, which were validated against experimental data. The resulting lamina properties were used to inform filament-winding design and stacking sequence of an 8L Type IV COPV using CADWIND . Manufacturing-consistent layups were exported to ABAQUS for global finite element analysis and burst-pressure prediction using the Hashin failure criterion. Comparative simulations performed for the neat and nano-modified composites indicate delayed damage initiation and increased predicted burst resistance for the nanosilica- and GNP-enhanced systems, enabling equivalent performance with reduced laminate thickness. The proposed framework provides a transferable, manufacturing-aware pathway from nano-modified resin development to COPV structural performance assessment. • Development of a manufacturing-driven multiscale methodology for COPVs using nanofiller-enhanced epoxy matrices. • Combined Mori–Tanaka and FE homogenization accurately predicts lamina and tow-scale elastic properties. • CADWIND-based stacking sequence optimization improves burst-pressure performance and thickness distribution. • Nanofillers significantly enhance tensile strength (up to ∼ 45% for GNPs) with minor increase in longitudinal modulus. • Full-scale 8L COPVs simulated, demonstrating improved structural performance and potential for weight reduction.