Effects of Stacking Sequence and Fiber Type on Mechanical Properties of Hybrid Polymer Composite Materials With Cost Assessment

ABSTRACT This study examines the mechanical behavior and failure mechanisms of hybrid polymer composite laminates reinforced with glass, carbon, and aramid fibers. Glass/carbon, glass/aramid, and carbon/aramid systems utilizing woven and twill reinforcements were fabricated using a five‐layer vacuum infusion process. A total of 24 stacking sequences were produced and tested under three‐point bending and tensile in accordance with ASTM standards; furthermore, densities were measured to quantify weight savings. Hybridization significantly influenced flexural and tensile responses, fracture modes, and ductility. The incorporation of ductile glass or aramid into brittle carbon laminates increased flexibility, while the stacking sequence governed load capacity. In glass/carbon hybrids, placing carbon in the outer layers with glass in the inner layers improved flexural strength and ductility; correspondingly, carbon/glass hybrids delivered the highest flexural strength. Delamination was the dominant failure mode under tension, whereas bending failures were characterized by fiber breakage and pull‐out. These results provide valuable guidance for designing lightweight, high‐performance composites for aerospace, automotive, and structural applications.