Regionally Tailored Layup Design with Bio-Inspired Features for Enhanced Load-Bearing Capacity and Damage Tolerance of CFRP Rectangular Beams

In nature, organisms have evolved unique structures that feature low weight, high strength, and damage resistance. The Eurasian eagle-owl serves as a representative example, with specialized feather architectures that enable stable flight in intense and turbulent airflow conditions. Herein, driven by classical design layup guidelines, and inspired by the distinctive fiber architecture of the feather shaft cortex, we propose a regionally tailored layup (RTL) design to enable mass-efficient composite beams with high load-bearing capacity and enhanced damage tolerance. The feather shaft reference lay-up rectangular beam (FSRB) adopts the RTL, and a flange overlap is introduced to preserve the integrity and strength of the flange–web interface; it is then manufactured using inner–outer matched molds in conjunction with vacuum bag molding. Three-point bending shows that the FSRB achieves a flexural strength of 180 MPa and a flexural modulus of 12.1 GPa. Relative to conventional axial (ALRB), Cross-ply (CPRB), single-helix (SLRB), and quasi-isotropic (QLRB) lay-up rectangular beams, the FSRB improves strength by 59.5%, 46.6%, 26.8%, and 21.2%, and increases modulus by 81.7%, 34.7%, 25.1%, and 10.8%, respectively. FEA and SEM observations confirm an RTL architecture in the rectangular beams, characterized by differentiated fiber arrangements in the flange and web. Flanges with an axially dominated layup provide high initial flexural strength and stiffness. The web, formed by a crossed-ply/axial hybrid layup, provides transverse support and redirects crack/delamination growth, thereby promoting progressive failure and enhancing energy dissipation. Overall, this RTL design enables concurrent improvements in load-carrying capacity and damage tolerance. This study offers a design perspective for high-performance load-bearing components.