Cordylus cataphractus-scale-inspired composite materials for stab resistance

Inspired by Cordylus cataphractus scales, two types of rectangular scale-like knitted fabrics (RSKF) were developed using ultra-high molecular weight polyethylene (UHMWPE) fibers. By constructing a unit geometry model and analyzing the knitting structure of RSKF, a scale-like knitted fabric imitating Cordylus cataphractus (SKFC) with multilayered and interlacing structures was designed. The SKFC can be combined with rigid composites to form a reinforced P-SKFC, exhibiting excellent protective properties (∼2203.98 N) and good flexibility (<250 mN cm). Due to its removable and replaceable hard protective blocks, P-SKFC exhibits good durability. This study offers guidance for the rapid development of P-SKFC and proposes a novel strategy for designing flexible, lightweight stab-resistant fabrics, potentially offering substantial advantages for personal stab-resistance devices in various industrial fields. • Cordylus cataphractus scale-inspired composite design enhances puncture resistance through effective impact force dispersion. • Advanced knitting techniques and digital program control form a multi-layer overlapping and interlocking skeleton structure. • The integration of soft knitted structure with rigid protective blocks balances flexibility and puncture resistance. • Created a reinforced fabric (P-SKFC) that offers high puncture resistance (∼2203.98 N) and good flexibility (<250 mN cm).