Numerical decoding of layer sequencing effects on impact resistance in multilayer high performance fabric panels-the critical role of yarn density, failure strain and modulus

In response to the critical demand for exploring and optimizing impact-resistant performance of hybrid-layer fabric panels in protective engineering applications, this study systematically investigates the low-velocity impact response mechanisms of hybrid-layer fabric panels through comprehensive parametric analysis. The developed finite element model innovatively integrates three key material characteristics (yarn density, failure strain, and longitudinal modulus) to establish optimal design of hybrid-layer panels. The findings reveal three groundbreaking design principles for hybrid-layer fabric panels: (1) Gradient optimization strategy demonstrating that decreasing yarn density from impact surface of fabric panel achieves highest energy absorption; (2) Hybrid-failure-strain fabric panel in which the middle layer possessed the greatest failure strain achieving the best improvement in impact-resistant performance; (3) Fabric arrangement according to decreasing yarn modulus from impact surface of fabric panel resulted in the highest energy absorption capacity. These fundamental discoveries advance the theoretical framework for protective material design in impact engineering, providing guidelines for developing next-generation protective systems in body armor applications.