Conformable Core Gas Tank

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Calumet, Michigan
Project Term:
09/01/2012 - 09/30/2016

Technology Description:

REL is developing a low-cost, conformable natural gas tank for light-duty vehicles that contains an internal structural cellular core. Traditional natural gas storage tanks are cylindrical and rigid. REL is exploring various materials that could be used to design a gas tank's internal structure that could allow the tank to be any shape. The REL team is exploring various methods of manufacturing the interconnected core structure and the tank skin to identify which combination best meets their target pressure-containment objectives. REL's conformable internal core would enable higher storage capacity than current carbon fiber-based tanks at 70% less cost. REL is developing small-scale prototypes that meet their durability, safety, and cost goals before scaling up to a full-sized prototype.

Potential Impact:

If successful, REL's foam core gas tank would provide improved storage capacity and fit easily into any natural gas vehicle, enabling their widespread use.


Improving the convenience of natural gas vehicle ownership could reduce our dependence on foreign oil and make consumers less vulnerable to sudden oil price shocks.


Natural gas vehicles produce approximately 10% less greenhouse gas emissions than gasoline-powered vehicles throughout the fuel life cycle.


Compressed natural gas currently costs half as much per gallon of gasoline equivalent. With the average American spending over $2000 per year on gas, enabling the use of natural gas vehicles could save drivers $1000 per year.


ARPA-E Program Director:
Dr. Jason Rugolo
Project Contact:
Dr. Adam Loukus
Press and General Inquiries Email:
Project Contact Email:


Endres Machining Innovations, LLC

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