In the development of the new energy cars, the rocket engine systems and the satellites, there are some special requirements, such as the high air tightness, the lightweight and the long-life, for the composite pressure vessels used to store the liquid propellant and high pressure gas. In this paper, a new method is proposed to design and prepare the lightweight composite pressure vessels with ultra thin metal liner. A characterization method for the slippage coefficient measurement between the fiber and the mandrel is developed. The Al alloy liners of 0.8mm in thickness are fabricated. A new stronger interface between the composite layer and the ultra thin Al alloy liner is designed according to the structure of the Gecko feet. A Self-healing technology is adopted to improve the reusable properties. With the lightweight composite pressure vessels, the weight can be saved by 70% as compared to the metal pressure vessels with the same volume and the same pressure.