Verification Through Testing

Steelhead Composites has earned flight and field heritage across a wide range of Aerospace, Space, and Defense (ASD) platforms—including vessels qualified under S-080, S-081, and multiple MIL-SPEC standards. Achieving this level of trust and certification requires rigorous, repeatable testing. That’s why we offer a comprehensive suite of in-house testing services tailored to the unique demands of ASD programs. Whether developing a next-generation propulsion system or qualifying a life-support tank for orbital use, Steelhead’s testing infrastructure and engineering expertise ensure a smooth path from prototype to flight-ready with confidence.

Engineer operating a computer-controlled pressure testing system at Steelhead Composites’ in-house test lab, with a composite pressure vessel undergoing hydrostatic testing.

At Steelhead, we test every pressure vessel like lives depend on it—because they do.

Our in-house test lab performs a full range of qualification and validation protocols to ensure every vessel meets or exceeds the stringent requirements of aerospace and defense applications. Testing capabilities include:

  • Hydrostatic Burst Testing – Determines ultimate vessel strength and validates safety margins.
  • Leak Testing – Uses helium mass spectrometry and pressure decay methods to confirm zero leakage in both operational and standby conditions.
  • Cycle Testing – Simulates thousands of pressure cycles to assess fatigue life and long-term reliability.
  • Thermal Conditioning – Exposes vessels to extreme temperature ranges to verify performance in space, high-altitude, and battlefield environments.
  • Dimensional & Structural Inspection – Ensures vessels meet precise tolerances for integration into complex aerospace assemblies.

Steelhead supports customers from early-stage R&D through final flight qualification. Our team collaborates closely with yours to define test plans, execute protocols, and deliver detailed documentation packages supporting certification with NASA, DoD, FAA, and commercial aerospace partners.

With decades of experience in composite pressure systems and a proven track record of successful flight programs, Steelhead is a trusted partner for pressure vessel validation in the most demanding environments.

Uses and Applications
Rocket stages under assembly in a spacecraft production facility, representing S-081 and S-080 qualification testing of pressure vessels for propulsion, life-support, and pressurization systems.

S-081 and S-080 Approval Testing

Qualification testing of pressure vessels for manned and unmanned spaceflight, including propulsion, life-support, and pressurization systems.

Stack of composite pressure vessels prepared for comparative testing, supporting performance benchmarking of weight, strength, and cost in aerospace applications.

Performance Benchmarking

Comparative testing of vessel designs, materials, and processes to optimize weight, strength, and cost for aerospace applications.

Polymer pressure vessel liner prepared for material evaluation, testing liner materials, overwraps, and bonding systems for compatibility with gases and environments.

Material Evaluation

Testing of liner materials, composite overwraps, and bonding systems to verify compatibility with stored gases and environmental conditions.

Close-up of a rocket engine stage with complex piping and pressure vessels, representing post-test and post-mission failure analysis to guide design improvements.

Failure Analysis Support

Post-test and post-mission evaluations to determine root causes, guide design improvements, and support corrective action plans.

Steelhead Composites burst chamber used for prototype and aerospace testing of high-pressure vessels under controlled failure conditions.

Steelhead’s burst chamber enables controlled testing of pressure vessels, validating performance and safety for aerospace, defense, and industrial applications.

Composite pressure vessel connected to a high-pressure cycle tester for validation at up to 10,000 psi with precise pressure control and electronic monitoring.
Composite pressure vessel inside a materials testing chamber at Steelhead Composites, used with a 2,200 lb Instron Load Frame, strain gauges, DSC, and 3D laser scanning for ASTM-compliant mechanical testing.
Composite pressure vessel positioned inside Steelhead Composites’ burst testing rig, rated to 30,000 psi, with strain gage mounting and continuous pressure vs. strain data collection.