NASA Spacecraft COPV Development
Space · Client: NASA
Project details
Collaborated with NASA to significantly improve the robustness and durability of spacecraft composite pressure vessels without adding unnecessary dead mass.
HyPerComp Engineering Inc.
A Heritage of Innovation
About the firm
HyPerComp Engineering Inc. specializes in the design, analysis, development, testing, manufacture, and certification of filament-wound high-pressure composite pressure vessels and structures. It provides specialized engineering for Type 2, Type 3, and Type 4 composite overwrapped pressure vessels (COPVs) serving aerospace, defense, automotive, and industrial clients.
- Established
- 1996
- Firm type
- Aerospace Engineering · Mechanical Engineering · Materials Engineering · Materials Testing
People
James PattersonPresident and Founder
Capabilities
Composite Vessel Engineering and Analysis
Provides full-lifecycle structural modeling for Type 2, Type 3, and Type 4 composite overwrapped pressure vessels, utilizing orthotropic finite element modeling and closed-form calculations.
- Filament Winding Structural Simulation
- Thick and Thin Wall Structural Optimization
- Cryogenic and High-Pressure Storage Engineering
- Ballistic Damage Tolerance Validation
Regulatory Compliance and Certification
Helps clients navigate global regulatory frameworks and standards to qualify high-pressure cylinders for international commercial and defense markets.
- Standards and Code Compliance Validation
- Third-Party Agency Coordination
Performance and Structural Testing
Executes physical verification and characterization of materials and finished vessels using high-pressure hydroburst, fatigue, permeation, and gunfire testing.
- Hydroburst Verification up to 30,000 psi
- Fatigue and Pressure Cycle Evaluation
- Gunfire and Penetration Validation
- Permeation and Material Characterization
- Non-Destructive Materials Evaluation
Process and Product Optimization
Mitigates technical and financial risk through analytical evaluations that support critical commercial development and manufacturing choices.
- Failure Mode and Effects Analysis
- Strategic Program Cost-Risk Evaluation
Prototyping and Toll Manufacturing
Fabricates specialized low-volume filament-wound composite structures and partners with high-volume production facilities to support scaling needs.
- Wet and Tow-Preg Winding Fabrication
- Specialized Low-Volume Cylinder Production
Technology Licensing
Offers commercial rights to proprietary fabrication and design technologies to support in-house client manufacturing programs.
Industries
Aerospace · Space · Defense · Oil & Gas · Automotive · Industrial · Medical Devices · Sports & Recreation
Projects
Hydrogen Automotive COPV Development
Automotive
Project details
Developed and supplied pioneering proof-of-concept extreme high-pressure gaseous and cryogenic compressed hydrogen composite overwrapped pressure vessels for leading automotive OEMs.
Military UAV Fuel Storage COPV
Defense · Client: US Military
Project details
Engineered and manufactured ultralight fuel storage composite overwrapped pressure vessels for US military unmanned aerial vehicles to achieve record-setting flight endurance.
High-Pressure Hydrogen Fuel Cell Vessel
Automotive
Project details
Designed and qualified the first commercial composite pressure vessel capable of withstanding 10,000 psig service pressure and extreme cycles for automotive hydrogen fuel cell applications.