Delivered a safe, lightweight hydrogen tank mounting solution for mobility van conversions by optimizing tank layout, frame design, and mounting durability under real-world driving and crash conditions.

Key Highlights:

• Conducted packaging feasibility studies for ceiling-mounted vs roof-mounted hydrogen tank layouts
• Compared two large tanks vs multiple smaller tanks for capacity-to-weight efficiency and overall vehicle integration
• Designed a lightweight aluminum frame utilizing existing roof rack mounts, with additional fasteners along the roof skin perimeter
• Integrated reinforcement brackets under the ceiling while clearing headliner, ducting, and other interior components
• Provided detailed drawings, fabrication support, and shims for streamlined installation
• Performed finite element analysis of tank mounts under durability events (jounce, twist, cornering, braking over bumps and potholes) using full vehicle models
• Conducted simplified crash analysis (30g fore-aft/lateral) to evaluate mounting frames and bracketry
• Sized and validated fasteners using InDepth’s proprietary fastener validation software