Bio-inspired design and optimization of 3D-printed Al2O3/UHMWPE composite armor for enhanced penetration resistance

Ceramic armor is extensively used in both military and civilian protection systems due to its high hardness and exceptional impact resistance, providing effective defense against ballistic threats. Enhancing the protective performance of Al2O3 ceramic/UHMWPE composite armor through bio-inspired structural optimization has emerged as a promising approach. In this study, a novel bio-inspired design was developed to achieve a balance of lightweight construction, flexibility, and improved impact resistance. Orthogonal experiments were conducted to evaluate the effects of key configuration parameters, including ceramic tile size, overlapping angle, layer thickness, and bullet impact position. A prototype sample was fabricated via 3D printing and subsequently sintered to assess its physical characteristics. Using experimentally measured parameters, finite element simulations were performed to identify the optimal structure. The best-performing configuration featured an overlapping-2 arrangement of aluminum oxide ceramic tiles with a 40° overlapping angle, 5 mm tile size, and 10 mm thickness. The minimum penetration depth occurred when the bullet struck at position 3. Overall, the optimized structure demonstrated a maximum improvement of 85.11% in penetration resistance. These results offer valuable guidance for further enhancing the protective capabilities of Al2O3/UHMWPE composite armor systems.