Kinda long winded here:
1) All tanks are designed to have unindicated reserve. These means at zero guage reading the tank still has some fuel. This is principally because of tolerances in the tank and fuel sender, and the OEM doesn't want a pissed off customer (and actually some potential liability here).
On the otherside is a thing known as unusable capacity. This is when the useful volume of the tank isn't indicated properly. More times than not it seems one can never achieve rated tank capacity filling from zero gauge indication. This results from tolerances and the fact that the OEM would rather have this condition than the former (where someone runs out of gas with gas indicated).
2) All tanks require an vapor dome above the full fuel level. This is primarily to accomodate temperature variations and the fact the gas in the tank must remain vented (to the carbon cannister) though roll over valves. Typically a vapor dome of 10% is used. All portions of the vapor dome must remain vented over the range of vehicle grades [30%] in all directions.
3) Vehicles today all have Onboard Refueling Vapor Recover [ORVR] systems. These use a liquid seal filler pipe technology where vapors created during fill are forced through and adsorbed the carbon cansiter. Fillers pipes today are about 1" in diameter and there is no longer a vent pipe coming back up along the fill pipe to the filler neck to spit out the shut off signal. [Some pipes may use a very small tubing to the filler neck (1/4"] but this is for another purpose.]
4) One can stuff the vapor dome of item 2 by slowly filling the tank after shut off. This is undesirable to overfill the tank. The EPA also doesn't want the spitback from overfill so signs at the pump now say to stop after the first shut-off. [Most OEMs assume and test using 3 shut-offs.]
5) Fill nozzles use a port on the end, look for a hole in the barrel just before the end, that constantly entrains air during fill. Inside the nozzle is also a venturi device to create a vacuum to suck air through the hole. If liquid touches this hole, air stops entraining and pressure drops thru the venturi system. A diapraghm in the nozzle is sensitive to this vacuum and will actuate the release of the handle input.
6) If one can repeatedly get more than rated capacity without resorting to overstuffing, then the tank shape might be distorted.
7) One more thing: Fuel pumps pump gas internally through the pump for cooling. One will not burn a pump out unless the pump runs completely dry for a period of time. Even normal cranking on a completely empty tank will be OK. The pump does not have to be surrounded by gas. Even so, most fuel pumps are enclosed in reservoirs designed so that the last pumpable quart of fuel of the tank is in the reservoir and around the pump.