The use of thermoplastic resins for high-pressure storage vessels is a topic of high interest across the industry. This is highlighted by key players such as Toyota, whose perspective on this technology is shared by Dr. Martin Kerschbaum, Manager of the ME22 R&D Material Engineering Division at Toyota Motor Europe NV/SA:
“The usage of thermoplastic resins for manufacturing of highpressure hydrogen storage vessels is of high interest for Toyota. This is due to potential advantages in terms of design, processing, performance, and circularity. It is essential to compare and evaluate the diverse options of design and manufacturing strategies for high-pressure vessels based on thermoplastic composite materials. Gaining additional insights into the key influencing factors on material efficiency, production scalability and realistic cost-structure scenarios is a crucial part of this process. AZL’s structured approach – a combination of know-how in applications, composite materials and production systems with expertise across the entire value chain – provides Toyota with valuable input for the further development of innovative storage systems.”
Building on this industry momentum, AZL Aachen GmbH has kicked off a new Joint Partner Project that sets out to redefine how thermoplastic pressure vessels are designed and manufactured. Launched in July 2025 under the title “Thermoplastic Pressure Vessel Production – Development and benchmarking of design-formanufacturing-strategies to optimize material efficiency and cost,” the initiative brings together companies from all parts of the pressure vessel and composite value chain to collaborate on sustainable, highperformance solutions for high-pressure storage. With an approximate duration of nine months, the project is already underway, and interested companies can still join at any time to benefit from and contribute to its results.
Thermoplastic composites have long been recognized for their potential to accelerate production processes, offer alternative recycling routes and enable greater design freedom. Yet, when traditional thermoset vessel designs are simply transferred to thermoplastic manufacturing, cost and efficiency often fall short of expectations. The new AZL-led project takes a holistic approach, rethinking vessel design from the ground up. By aligning the unique properties of thermoplastic materials with optimized design-for-manufacturing strategies, the project aims to unlock their full economic and technological advantages for applications such as hydrogen and compressed natural gas (CNG) storage.
The Joint Partner Project format ensures that this development is driven by the collective expertise and priorities of its participants. Companies joining the consortium co-finance the work, shape the technical direction, and engage directly with the AZL Engineering Team. The work plan includes a detailed analysis of current thermoplastic pressure vessel technologies, the development of new design concepts, and a comprehensive benchmarking of configurations in terms of weight, cost, recyclability and key production metrics. All results are generated within a unified evaluation framework, giving partners clear, comparable data to inform their own product strategies.
Beyond technical development, the project provides a platform for strategic networking and exchange. Through interactive meetings and workshops, each partner can contribute their own perspectives, learn from consolidated industry knowledge, and gain early access to simulation results, concept layouts and cost analyses. Drawing on over a decade of experience in managing collaborative R&D projects, AZL ensures that the process is structured, transparent and geared towards delivering actionable outcomes for all involved.
With the project now in progress, new partners are welcome to join and become part of a dynamic consortium shaping the next generation of thermoplastic pressure vessels. Participation offers not only insight into the latest engineering approaches but also the opportunity to directly influence the development of scalable, costefficient and recyclable high-pressure storage solutions.
🔥Join now to gain early access to cutting-edge designs, detailed benchmarking data, and a unique network of industry leaders driving the future of thermoplastic pressure vessel production.
