AbstractIn this study, optimal angle‐ply orientation of symmetric composite cylinders under fatigue loading is investigated. The fiber‐reinforced plastic cylinders were manufactured from E‐glass/epoxy. The layers were manufactured symmetrically in [±75°]2, [±60°]2, [±55°]2, and [±45°]2 orientations. Burst pressure of filament‐wound composite cylinders under alternating pure internal pressure was measured experimentally. Internal fatigue pressure testing method was applied to the composite cylinders in close‐ended condition. For this study, a PLC controlled hydraulic pressure testing machine has been employed. The static burst pressure values of specimens were measured; subsequently, fatigue test pressure was applied in 70, 60, and 50% stress levels of burst pressure for each orientation. Damage propagations of the composite cylinders on these stress levels were observed as whitening, leakage, and final failure for [±60°]2, [±55°]2, and orientations. When the damage propagation of [±75°]2 angle‐ply cylinder was observed, whitening and leakage did not occur and final failure occurred suddenly. Stress‐cycle curves obtained from the tests are given in graphics. Experimental results reveal that variation in stress levels and the winding angles have considerable effects on final failure cycles, which is also presented graphically. The optimum winding angle for the composite pressure cylinders or vessels under internal fatigue pressure load was obtained as [±45°]2 orientation. POLYM. COMPOS., 2010. © 2009 Society of Plastics Engineers