Investigating the Surface Defects and Structural Integrity of 3D Printed Hydrogen Storage Cylinders in UAV Applications

Year : 2025 | Volume : 13 | Special Issue 03 | Page : 161-191
    By

    Kirubadurai. B,

  • Jaganraj R,

  • Jegadeeswari. G,

  • Vinothkumar M,

  1. Assistant Professor, Department of Aeronautical Engineering, Vel Tech Rangarajan Dr. Sagunthala R&D Institute of Science and Technology, Tamil Nadu, India
  2. Associate Professor, Department of Aeronautical Engineering, Vel Tech Rangarajan Dr. Sagunthala R&D Institute of Science and Technology, Tamil Nadu, India
  3. Assistant Professor, Department of Electrical and Electronics Engineering, Saveetha Engineering College, Tamil Nadu, India
  4. Assistant Professor, Department of Aeronautical Engineering, Vel Tech Rangarajan Dr. Sagunthala R&D Institute of Science and Technology, Tamil Nadu, India

Abstract

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This research explores the processing and manufacturing challenges of 3D printed polymer composites for high-pressure hydrogen storage in UAVs. The study focuses on addressing surface integrity and structural robustness issues inherent in additive manufacturing. Finite Element Analysis (FEA) was conducted on four thermoplastic polymer ABS, PET-G, HDPE, and Nylon to assess their mechanical performance under 35 MPa of pressure. Results revealed that PET-G and ABS provided better stress distribution and deformation behaviour, identifying them as optimal candidates for further testing. Despite promising FEA results, the manufacturing process faced challenges in achieving adequate surface finish, with issues such as inherent roughness, visible layer lines, and microscopic voids in the printed cylinders. These surface defects are problematic as they serve as stress concentrators, reducing the structural integrity and safety of the cylinders under operational pressures. To evaluate the extent of these defects, non-destructive testing (NDT) techniques were applied, including multi-spectral imaging for assessing surface roughness, ultrasonic testing for detecting internal flaws, and dye penetrant testing for surface-level imperfections like micro-cracks. Experimental findings revealed significant manufacturing flaws: multi-spectral imaging highlighted surface roughness inconsistencies, ultrasonic testing uncovered internal voids and uneven material distribution, and dye penetrant testing exposed surface defects due to poor inter-layer bonding. These results underscore the limitations of current additive manufacturing processes in producing high-quality polymer composites suitable for high-pressure applications. In conclusion, PET-G and ABS show potential as materials for hydrogen storage in UAVs, but challenges related to surface finish and internal structure remain critical. The study emphasizes the need for improved 3D printing and post-processing techniques to create smoother, defect-free surfaces and consistent internal structures. Advancing these methods is essential to enhance the safety, reliability, and longevity of polymer-based hydrogen storage systems, offering valuable insights for aerospace and high-stakes industrial applications.

Keywords: 3D printed polymer composites, thermoplastic polymers, deformation behaviour, non-destructive testing (NDT), multi-spectral imaging.

[This article belongs to Special Issue under section in Journal of Polymer and Composites (jopc)]

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How to cite this article:
Kirubadurai. B, Jaganraj R, Jegadeeswari. G, Vinothkumar M. Investigating the Surface Defects and Structural Integrity of 3D Printed Hydrogen Storage Cylinders in UAV Applications. Journal of Polymer and Composites. 2025; 13(03):161-191.
How to cite this URL:
Kirubadurai. B, Jaganraj R, Jegadeeswari. G, Vinothkumar M. Investigating the Surface Defects and Structural Integrity of 3D Printed Hydrogen Storage Cylinders in UAV Applications. Journal of Polymer and Composites. 2025; 13(03):161-191. Available from: https://journals.stmjournals.com/jopc/article=2025/view=0



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Special Issue Subscription Original Research
Volume 13
Special Issue 03
Received 21/10/2024
Accepted 30/11/2024
Published 09/04/2025
Publication Time 170 Days
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