AIR-HGEN delivers an optimal design of the Type 4 composite pressure vessel for hydrogen storage in aircrafts, targeting on reducing weight, taking into account defects, coming from real case manufacturing scenarios monitored by a digital twin. A pressure vessel made from CFRP that withstands max. 500-600 bar (depending on topology optimization) is designed and prototyped, aiming at reliable, lightweight design, considering the application in aviation. Regarding the manufacturing, the pressure vessel is manufactured with the filament winding method(FW). The know-how for this method is provided by the Industrial partner, B&T Composites, which is a leading stakeholder in composites manufacturing in South-East Europe.