Specialists in the Design and Manufacture of Advanced Composite Structures

Hi-DEN: High Density Energy Network

Carbon ThreeSixty is leading a project to develop a novel high pressure Hydrogen storage solution for use with fuel cell systems for land transport and short haul aerospace.

Fuel Cell Electric Vehicles (FCEVs) are a key tool in the decarbonisation of both land and air transport vehicles and require high pressure Hydrogen storage systems. Carbon ThreeSixty’s Hi-DEN (high density energy network) system, based on volumetrically efficient arrays of “micro” hydrogen vessels enables huge increases in storage capacity, efficiency and vehicle range. The Hi-DEN system greatly improves volumetric efficiency, filling wasted space around conventional cylindrical pressure vessels. Storage volume increases by up to 50% for irregularly shaped spaces, such as those typically used for vehicle petrol or diesel tanks.

The system also offers improved gravimetric efficiency (kg H2 / kg structure), hence additional capacity and vehicle range do not come with a corresponding weight penalty. For volume manufacture the cost of hydrogen storage vessels is dominated by carbon fibre cost and “balance of plant”  components. Improved material usage efficiency therefore enables cost savings in material as well as space utilisation.

Carbon ThreeSixty leads the project and completes the design and development of the vessel, Antich & Sons are responsible for developing 3D woven preforms which enable the design concept and Viritech will develop the tank and fill control system as well as integrating / demonstrating the system in Viritech’s FCEV powertrains and providing a route to market.

The Hi-DEN project will build and test a fully functional prototype Hydrogen storage vessel to demonstrate these benefits for Viritech’s range of FCEV vehicles. 



Andy Smith, R&D Director at Carbon ThreeSixty said “We’re excited to be leveraging our composite expertise to bring innovation to the gaseous Hydrogen storage space and to be able to improve the capability, range and ultimately commercial viability of FCEV vehicles”

The project is funded by the Niche Vehicle Network which provides collaborative funding for research and development activities within niche vehicle manufacturing, with an emphasis on vehicle electrification, zero emissions, and light-weighting. 

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Notes to Editors

Carbon ThreeSixty is a turnkey provider for the design, development and manufacture of highly challenging, advanced composite structures. We are a valued partner in the delivery of innovation, engineering and manufacturing services to the Aerospace, Automotive, Energy and Defence sectors. We specialise in resin transfer moulding (RTM) processes and novel preforming techniques such as tailored fibre placement (TFP) to produce highly optimised and cost-effective structures. https://www.carbonthreesixty.com