Stress Mitigation and Impact Energy Dissipation in Bioinspired Vertically Layered Architected Composites

ABSTRACT The inherent conflict between stiffness and energy absorption has long constrained the development of high‐performance impact‐resistant materials. Vertically layered structures (VLS), which have evolved convergently in biological load‐bearing tissues such as horse hooves, bone, and wood, provide a compelling bioinspired solution. These structures feature alternating stiff and compliant micro‐laminates aligned parallel to the loading directions, enabling efficient load transfer and synergistic energy dissipation. Here, we fabricated 3D‐printed VLS composites integrating carbon‐fiber‐reinforced stiff matrices with engineered compliant interlayers. Combined mechanical testing and finite element simulations demonstrate that VLS outperforms conventional horizontally layered structures by increasing energy absorption by 18% and reducing peak impact force by 20%. This performance enhancement originates from controlled layer buckling, localized plastic deformation, and effective stress redistribution, which collectively suppress crack propagation and improve damage tolerance without compromising structural stiffness. Preliminary validation in protective outsoles and helmets confirms that VLS composites attenuate transmitted impact forces by up to 30% at low strain rates, significantly mitigating stress concentrations in underlying biological tissues. This work establishes a scalable, bioinspired design strategy for lightweight, high‐stiffness, and highly damage‐tolerant protective materials, with broad implications for next‐generation personal protective equipment and impact engineering.