Influence of Thermoplastic Polyurethane Content on Interlaminar Adhesion of Hot‐Pressed Aramid Fabrics

ABSTRACT This study examines the interlaminar adhesion of aramid composite laminates bonded with thermoplastic polyurethane (TPU) films and fabricated via hot pressing. Optimal processing parameters 200°C, 10 MPa, and 25 min were identified through a Design of Experiments (DOE) approach, resulting in a 67% improvement in T‐peel strength over non‐optimized samples. Laminates with TPU contents ranging from 13.90 to 38.10 wt.% were produced, with the best adhesion observed at 29.90 wt.% (two TPU layers), where enhanced matrix diffusion promoted interfacial bonding. In contrast, excessive TPU reduced adhesion into the fiber bundles. The intermediate formulation exhibited 21% higher peel strength than the lowest‐content laminate. Dynamic mechanical analysis indicated lower activation energy for segmental motion at the optimal composition, reflecting improved matrix–fiber interaction. These findings offer valuable insight for designing aramid‐TPU composites with enhanced energy absorption and delamination resistance, particularly for protective and ballistic applications, while guiding the selection of matrix content and processing conditions for structural optimization.