Influence of Z-yarn interlacing pattern on ballistic performance of 3D orthogonal woven fabrics

Three-dimensional orthogonal woven fabrics (3DOWFs) represent a promising class of materials for advanced ballistic protection, primarily due to their superior resistance to delamination compared with traditional 2D laminated composites. However, the influence of the specific through-thickness binding architecture on impact performance is not yet fully understood. This study utilizes high-fidelity finite-element modeling to investigate how the weaving pattern governs energy absorption and failure mechanisms under ballistic impact. We analyze two distinct through-thickness architectures: a “tight” weave with frequent Z-yarn interlacing (a one-step pattern) and a corresponding “loose” weave with a less-frequent, more spaced-out interlacing pattern (a three-step pattern). This comparison allows for a direct investigation into the role of architectural constraint on ballistic energy absorption. The results demonstrate that the looser three-step architecture exhibits significantly enhanced ballistic performance. This is attributed to greater in-plane yarn mobility, which allows for a larger volume of material to be engaged during the impact event, leading to more effective energy dissipation. Conversely, the tightly constrained one-step pattern restricts yarn movement, leading to localized failure and a lower ballistic limit. These findings highlight a critical design principle: optimizing the Z-yarn binding pattern to balance structural integrity with yarn mobility is crucial for maximizing the ballistic performance of 3D woven fabrics.