Method of manufacturing complex-shaped, flexible, and reusable tanks

A method of fabricating a seamless fuel tank, the method comprising:

• 3D-printing a mold, the mold including a body having a first side wall, a second side wall opposite the first side wall, an inner surface, an outer surface and a nozzle extending outwardly from and supported by the second side wall, the first side wall having a first wall thickness and the second side wall having a second wall thickness that is greater than the first thickness, the outer surface having a concave portion and a convex portion;
• connecting a pressure source to the nozzle on the mold;
• inflating the mold via the nozzle;
• forming a seamless, flexible fuel tank by layering-up a plurality of layers over the outer surface of the inflated mold via additive manufacturing, the flexible fuel tank having a port formed about the nozzle, and the tank surrounding the mold;
• deflating the mold;
• and
• withdrawing the mold through the port of the fully formed, flexible fuel tank,
• wherein the mold is a male mold, and
• wherein the mold is fabricated from a durable and rigid material having a Shore A rating between 20 and 95.