A novel dual-faced structured fabric with 3D hollow structure for tunable and robust mechanical properties

Structured fabrics with tunable mechanical properties show promise for applications in wearable technologies, soft robotics, and biomedical support systems. However, their mechanical robustness and ability to dynamically adapt to varying external forces remain limited for advanced biomedical and robotic applications. To address these challenges, the paper presents a novel dual-faced structured fabric composed of 3D hollow unit cells interlocked in a chain mail configuration, featuring distinct unit cell arrangements on the top and bottom surfaces. Under increasing pressure, the architected structure exhibits enhanced inter-unit contact, enabling a reversible mechanical transition from a flexible to a stiffened state. Under low vacuum confining pressure, the fabric achieves an impressive load-carrying capacity—withstanding loads up to 40 times its weight—and exhibits a specific strength of 13,387 N·m·kg -1 and a specific energy absorption of 3,488 J·kg -1 , three times higher than conventional multi-lattice structures and foams. Additionally, the fabric's flexible structure exhibits excellent mechanical performance under impact testing, demonstrating strong suitability for impact protection. The enhanced durability is attributed to the synergistic strengthening between adjacent unit cells and their uniquely interlocked topology. This innovative design will expand the application potential of fabric-based materials in high-performance scenarios, including body armor, protective packaging, and multifunctional medical support systems.