Abstract: In an embodiment, an aircraft includes a fuselage; a propulsion system powered by a fuel; and a fuel cell configured to store the fuel, the fuel cell including an inner layer configured to contact the fuel; an outer layer; and a self-sealing fabric structure formed from ultra-high molecular weight polyethylene (UHMWPE), the self-sealing fabric structure being between the inner layer and the outer layer, the self-sealing fabric structure being configured to self-seal a hole formed in the inner layer and the outer layer by a projectile.

Abstract: A fuel cell containing fuel for an aircraft includes an innermost layer configured to contact the fuel, an outermost layer and a containment gel formed from isocyanate and polyol interposed between the innermost and outermost layers. The containment gel is configured to self-seal a ballistically formed hole therein, thereby reducing leakage of the fuel from the fuel cell.

Abstract: A method of fabricating a tank includes connecting a pressure source to a nozzle on a male mold, inflating the male mold via the nozzle, forming a tank by applying at least one layer over the outer surface of the male mold, the tank having a port formed about the nozzle, deflating the male mold, and withdrawing the male mold through the port. A method of fabricating a tank includes 3D-printing a male mold, connecting a pressure source to a nozzle on the male mold, inflating the male mold via the nozzle, forming a tank by applying at least one layer over the outer surface of the male mold, the tank having a port formed about the nozzle, deflating the male mold, and withdrawing the male mold through the port. A method of fabricating a tank includes forming a tank on a mold formed from a foam blocks.

Abstract: An explosion suppression insert for a fuel tank includes a hollow body having an inner surface and an outer surface, the hollow body being made of an explosion suppressing material; and a plurality of perforations defined in the outer wall. In some embodiments, a nonwoven explosion resisting insert for a fuel tank includes a body including a plurality of interconnected non-woven fibrous struts being made of an explosion suppressing material, the body having a first end and a second end; and a plurality of voids defined by the plurality of struts, the voids being configured such that the body has a porosity of between 5 pores per inch and 50 pores per inch. Methods of manufacturing explosion resisting inserts are also provided.

Abstract: In an embodiment, a fuel cell includes: a flexible substrate including a first fuel-tolerant material; a fitting on the flexible substrate, the fitting including first openings extending through an outer portion of the fitting; a primer coating on the outer portion of the fitting, the primer coating including a second fuel-tolerant material; first yarns strung through the first openings of the fitting, the first yarns stitched into the flexible substrate; and an encapsulant encapsulating the first yarns, the primer coating, and the outer portion of the fitting, the encapsulant disposed on the flexible substrate, the encapsulant including a third fuel-tolerant material, the third fuel-tolerant material chemically bonded to the second fuel-tolerant material and the first fuel-tolerant material.

Abstract: A method of manufacturing a seamless, non-wicking containment bladder includes providing yarn materials, coating the yarn materials with a precursor protective coating, loading the yarn materials into an additive manufacturing process, depositing the yarn materials in pre-selected amounts and locations to form a desired structure, forming and heat-setting, and coating the seamless bladder.