A method of manufacturing a high-pressure composite pressure vessel for high-pressure being at or above 70 bar (1000 PSI or 7 MPa) includes providing an expandable core vessel defining a hoop section between end domes. An aligned discontinuous fiber composite material is wrapped over the expandable core vessel aligning with a plurality of load paths present in the expandable core vessel being over the hoop section and end domes. The aligned discontinuous fiber composite material has fibers in a prepreg tape that are at least 5 mm in length to 100 mm in length or less. Next, a continuous fiber-reinforced composite is wrapped over the aligned discontinuous fiber-reinforced composite along the hoop section and not wrapped along the end domes. The expandable core vessel may be pressurized and heated to consolidate the composite overwrap. Finally, the vessel is cooled under pressure resulting in the high-pressure composite pressure vessel.

Systems and methods are provided for fabricating a laminate. One method includes laying up a first set of layers comprising tows of unidirectional thermoplastic fiber-reinforced material for the laminate, and laying up a second set of layers comprising tows of braided thermoplastic fiber-reinforced material for the laminate.

Systems and methods are provided for fabricating a laminate. One method includes laying up a first set of layers comprising tows of unidirectional thermoplastic fiber-reinforced material for the laminate, and laying up a second set of layers comprising tows of braided thermoplastic fiber-reinforced material for the laminate.

Annular structures formed using composite materials and systems and methods for forming annular structures using composite materials are provided. The composite materials can include fiber reinforced thermoplastic materials. The annular structures include a number of component parts. Each component part can be in the form of a strip of fiber reinforced thermoplastic material that extends around all or a portion of a circumference of the structure. The ends of the component parts can be staggered, so that they a placed at different locations about the circumference of the structure. Methods for forming annular composite structures include wrapping one or more strips of fiber reinforced thermoplastic material having one or more layers about a mandrel, and fusing the strips to form an integral annular structure.

Annular structures formed using composite materials and systems and methods for forming annular structures using composite materials are provided. The composite materials can include fiber reinforced thermoplastic materials. The annular structures include a number of component parts. Each component part can be in the form of a strip of fiber reinforced thermoplastic material that extends around all or a portion of a circumference of the structure. The ends of the component parts can be staggered, so that they a placed at different locations about the circumference of the structure. Methods for forming annular composite structures include wrapping one or more strips of fiber reinforced thermoplastic material having one or more layers about a mandrel, and fusing the strips to form an integral annular structure.

A method for forming a composite fluid conduit includes providing an inner pipe having a variation in cross-section between at least two different longitudinal sections thereof and applying a fiber reinforced composite material to the inner pipe. In some disclosed examples the variation in cross section may be provided intermediate opposing ends of the inner pipe. In other disclosed examples the variation in cross section may be provided at an end region of the inner pipe.

A method for forming a composite fluid conduit includes providing an inner pipe having a variation in cross-section between at least two different longitudinal sections thereof and applying a fiber reinforced composite material to the inner pipe. In some disclosed examples the variation in cross section may be provided intermediate opposing ends of the inner pipe. In other disclosed examples the variation in cross section may be provided at an end region of the inner pipe.

A method produces a high-pressure gas storage container that includes a liner and a reinforcing layer. The liner houses a high-pressure gas. The reinforcing layer is formed by winding a plurality of strip-shaped reinforcing members around an outer perimeter surface of the liner. The method includes irradiating plasma on at least a portion of the reinforcing fibers, and adjusting an irradiation intensity of the plasma such that an irradiation amount of the plasma with respect to the reinforcing fibers becomes constant in accordance with changes in a transport speed of the reinforcing fibers.

Provided are a novel filament for a three-dimensional printer, a winding, a method for producing a filament for a three-dimensional printer, and a method for producing a formed article. The filament for a three-dimensional printer includes a continuous reinforcing fiber impregnated with a thermosetting resin composition containing a thermosetting resin, the filament having a characteristic of being solid at 25° C.

A high-pressure tank includes a liner for storing a fluid, and a reinforcing layer covering an outer surface of the liner and including a fiber wound around the liner and a resin. The reinforcing layer includes a helical layer group including laminated helical layers, and a large-angle layer provided adjacent to the helical layer group and on the liner-side. The helical layer group includes an innermost layer that is closest to the liner and that is one of first and second helical layers respectively having the largest and second largest fiber winding angles, an outermost layer that is closest to an outer surface of the high-pressure tank and that is the other one of the first and second helical layers, and an intermediate layer disposed between the innermost and outermost layers and including a helical layer that is smaller in winding angle than the innermost and outermost layers.