Abstract: A pressure vessel includes a carbon fiber reinforced plastic with an integrated permeation barrier as its innermost layer. Alternating layers of permeation barrier and carbon fiber reinforced plastic may also be used. During manufacturing, the permeation barrier is sprayed on and integrated into the composite. The vessel, which is well-suited for high pressure gas storage is lighter weight than prior art vessels and has more usable volume than same-dimensioned prior art vessel. The permeation barrier encapsulates one or more ports or fittings of the vessel to reduce or eliminate the potential for gaps through which gas can escape. In one embodiment, a removable tooling process is employed in the manufacture of the vessel. In another embodiment, a permanent tooling process is employed and the tooling serves as a sorbent material for the vessel.