3D Woven Fabrics Research Articles

Fluid-Dynamics-Rectified Chemical Vapor Deposition (CVD) Preparing Graphene-Skinned Glass Fiber Fabric and Its Application in Natural Energy Harvest.

Graphene chemical vapor deposition (CVD) growth directly on target using substrates presents a significant route toward graphene applications. However, the substrates are usually catalytic-inert and special-shaped; thus, large-scale, high-uniformity, and high-quality graphene growth is challenging. Herein, graphene-skinned glass fiber fabric (GGFF) was developed through graphene CVD growth on glass fiber fabric, a Widely used engineering material. A fluid dynamics rectification strategy was first proposed to synergistically regulate the distribution of carbon species in 3D space and their collisions with hierarchical-structured substrates, through which highly uniform deposition of high-quality graphene on fibers in large-scale 3D-woven fabric was realized. This strategy is universal and applicable to CVD systems using various carbon precursors. GGFF exhibits high electrical conductivity and photothermal conversion capability, based on which a natural energy harvester was first developed. It can harvest both solar and raindrop energy through solar heating and droplet-based electricity generating, presenting promising potentials to alleviate energy burdens.

Characterization of pressure-dependent nonlinear bending behavior of yarns and its application in modeling the compression of 2D woven fabrics

This paper investigates the pressure-dependent nonlinear bending behavior of yarns, which is essential for the application of the virtual fiber modeling (VFM) method in the mechanical analyses of fabrics. An experimental method, along with a theoretical model based on classical beam theory, is presented to characterize the varying bending stiffness of yarns under different pressures. A tailored beam user element is then developed, incorporating the nonlinear bending behavior and combined with a truss element to create a physics-based virtual fiber formulation. Utilizing this formulation, the original kinematic VFM method is extended for modeling the mechanical response of 2D woven fabrics under compression. The predicted results of the proposed model closely match the reported experiment, demonstrating the significance of introducing the nonlinear bending behavior of yarns. This method can be a valuable tool for the fabric compression process and generating realistic mesoscale geometries for textile composites.

A numerical study on the effects of fabric structure on the impact resistance of 3D interlock woven fabrics

Three-dimensional (3D) woven fabrics have emerged as an effective structure for ballistic protection due to their flexibility, multi-impact resistance, and ability to form complex shapes. However, the influence of different 3D fabric architectures on ballistic performance is not fully understood. This study investigates the ballistic response of three types of 3D angle-interlock woven fabrics (3DTAWF, 3DSSWF, 3DSBWF) using numerical simulations with experimentally validated material models. Full-scale fabric models enable examining the dynamic behavior at the yarn level. Results show 3DSBWF exhibits the best ballistic performance with higher ballistic limit and energy absorption compared to 3DTAWF and 3DSSWF. Damage evolution indicates 3DSBWF and 3DSSWF have better structural integrity during penetration. The higher warp density and straighter warp path contribute to balanced warp-weft energy absorption and improved impact resistance in 3DSBWF. This study elucidates the role of 3D fabric structure on energy absorption patterns and failure morphology. The findings provide valuable insights into 3D woven fabric designs for optimizing ballistic protection performance.

Influence of the Structure of 3D Woven Fabrics on Radiation Heat Resistance and Thermophysiology Properties

The goal of this study was to investigate the influence of structural and constructional parameters of 3D fabric on two of the most significant properties of fabrics for thermal protection—resistance to radiation heat and thermophysiological properties. Today’s textile materials provide high thermal protection, but they display poor thermophysiological properties in extreme conditions. Six samples of 3D fabrics were developed using a laboratory weaving machine. The examined samples were made of identical warp, with a total of three different weft densities, and were woven in two different weaves. The conditions of the weaving process and construction were the same. EN ISO 6942:2022 and EN ISO 11092:2014 methods were used to determine the resistance of the samples to thermal radiation and thermophysiological properties. The results showed that the samples that contained folds in their structure with a larger volume of “trapped” air had better thermophysiological properties and better resistance to thermal radiation. The volume of air contained in the 3D structure was used as a thermal insulator and it did not have a negative effect on the thermophysiological properties. The described structure enabled the 3D fabric to have an optimal ratio of thermal protection and comfort, which is of crucial importance for fabrics used to make thermal protective clothing.

Investigation of forming process and deformation mechanisms of 3D warp interlock fabric

This article introduces a modeling method aimed at predicting the internal geometric structure of 3D warp interlock fabric. Inspired by the digital element method, the method employs truss elements to model the yarns as fiber bundles, and considers their material properties. This technique allows for predicting the microstructure of 3D woven fabric based on simple input characteristics. By varying the elastic modulus of virtual fibers, the friction coefficient between fibers, and the tension load at the ends of yarns, and designing compression molding molds to compress the fabric into shape, the virtual fiber fabric predicted the influence of variables on the fabric. The study found that the structure of the samples obtained through CT scanning is generally consistent with the structure of the virtual fiber fabric. The elastic modulus has a relatively minor impact on the fabric structure, whereas the friction coefficient and tension load significantly affect the cross-sectional shape of the yarns. During compression molding, deformation within the mold leads to interlayer fabric slippage and changes in the cross-sectional shape of the fabric. This suggests the feasibility and applicability of virtual simulation testing methods for analyzing the behavior of various types of 3D woven fabrics.

A mapping-based method capturing the mesoscopic morphological characteristics of 3D woven fabric torsion structures

Upon torsional molding, 3D woven fabrics accommodate a complex mesoscopic morphology that significantly governs the mechanical properties of composite structures. This paper is aimed to propose a macro-mesoscopic mapping method for characterizing the mesoscopic morphology of 3D woven fabric torsion structures. To this end, hyperelastic constitutive molding simulations of fabrics are performed to determine the macroscopic deformation profile within the structure in first. Then the mesoscopic details are resolved with the unit cell deformed accordingly at each digital element. A macro-mesoscopic mapping relationship is thus established by constructing a multiscale topological description function so as to tune the mesoscopic unit cells in consistency with the macroscopic manifold. Finally, the collection of mapping data is utilized for geometric reconstruction, establishing a mesoscale geometrically refined descriptive model about the torsion structure. The mesoscopic morphology of the reconstructed model is shown to agree well with experimental results. Moreover, the mapping method offers a significant time-saving strategy as the calculation time is only within a few minutes on a personal computer, in comparison with existing treatments necessitating 2-day computation on a workstation against similar tasks. The applicability of the present method to resolve other multiscale manifolds is also demonstrated.

A comparative study on ballistic performance of 3D woven fabrics under different boundary conditions

The potential of 3D woven fabrics as impact resistant material is increasingly recognized. Clarifying their ballistic response under varying boundary conditions is essential prior to deployment. This study aims to investigate the influence of various boundary conditions on the ballistic performance of 3D woven fabrics. Three aramid interlock woven fabrics, each with the same layer count, were designed and fabricated. A verified finite element model of ballistic impact at the yarn level was constructed for a comprehensive analysis. The influence of various boundary conditions on ballistic performance, including ballistic curve, stress distribution, back deformation, and energy absorption, is analyzed. It indicates that boundary conditions significantly affect the impact resistance and response mechanism of the fabrics. Among the different conditions, the fabric under Warp-sides held exhibits greater sensitivity. In the study, the fabric with vertical through-thickness warp yarn structure has smaller out-of-plane displacement, while the fabric with a multi-layer warp yarn structure exhibits better stability in energy absorption performance. The study investigates the response and performance of fabric configurations subject to various boundary conditions, and findings are valuable for the creation of 3D woven fabric designs that leverage boundary effects.

Numerical Analysis of the Ballistic Impact Behavior of 2D Woven Fabrics

Numerical Analysis of the Ballistic Impact Behavior of 2D Woven Fabrics

Simulation-based evaluation of effects of fabric structure on thermal conductivity of various 2D woven composites

The thermal conductivities of woven composites are strongly affected by the anisotropic properties of the reinforcing fibers, and thus by the fabric structure. In this study, the thermal conductivity of 2D woven composites was investigated by optimizing the fabric structures to enhance the through-thickness and in-plane thermal conductivities. Multiscale finite element models were developed to simulate the thermal behavior of various 2D fabric structures and evaluate their thermal performance under varying conditions, focusing on the effects of fiber tow undulation, dry-zone porosity, and matrix-rich zones. Fabric architectures were selected based on common 2D weavings of composites. The results showed that the tow undulation substantially enhanced the through-thickness conductivity and mitigated the impact of porosity. In addition, a higher tow anisotropy increased the effect of undulation. Moreover, the plain-weave fabric structures exhibited the highest through-thickness and in-plane thermal conductivities among the evaluated 2D woven fabrics in porous composites. Finally, the matrix-rich zones showed a stronger effect on the through-thickness than on the in-plane thermal conductivity of the 2D woven composites.

Augmenting the mechanical performance of three‐dimensional woven composites by the synergistic effect of fabric architecture and interfacial interaction of carbon nanotubes

AbstractThree‐dimensional (3D) woven fabrics offer many advantages over planar woven fabrics for composite applications. Because of the complex structure of 3D woven fabrics, an in‐depth investigation is needed to understand the effects of fabric architecture and nanofillers on the mechanical and failure behavior of 3D woven composites. The present study investigates the effect of 3D woven ultrahigh‐molecular‐weight polyethylene (UHMWPE) orthogonal fabric architecture, with or without nanofillers, on the mechanical properties of composites. 3D woven orthogonal fabrics with varying proportions of stuffer‐to‐binder (S/B) yarns were manufactured and reinforced with an epoxy (EP) matrix. Multiwalled carbon nanotubes (MWCNTs) were infused as nanofillers to improve the interaction between the UHMWPE fabric and the EP matrix. 3D woven composite having an S/B ratio of 2:1 showed the maximum tensile strength and toughness. On the other hand, 3D woven composite with an S/B ratio of 4:1 showed higher flexural strength and impact resistance. The failure mechanism was also studied by examining the fractured surfaces of composites, which revealed matrix cracking, fiber pullout, predominant binder yarn failure, and yarn slippage. From this study, it is understood that for 3D fabric reinforcement, a balance between structural integrity and load‐bearing capacity of yarns is decisive, whereas for the matrix, the incorporation of MWCNTs is found to be advantageous.Highlights The role of structure of 3D woven orthogonal fabric on the mechanical behaviour of the UHMWPE‐epoxy composite is investigated. The addition of functionalized MWCNTs improves the tensile, flexural, and impact properties. The decisive role of the ratio of stuffer‐to‐binder yarns is established. Matrix cracking, debonding, and yarn failure are observed during tensile failure.

Ballistic performance and damage behavior of three-dimensional angle-interlock woven fabric under ballistic impact: Numerical investigation

3D woven fabrics possess excellent specific performance and processability, making them highly favorable in the field of protective engineering, particularly in applications such as body armor. It is critical to evaluate their ballistic response under various impact loadings for both material manufacturing and application purposes. This paper presents a full-size mesoscale finite element model to investigate the dynamic damage behavior of 3D angle-interlock woven fabric (3DAWF) under ballistic impact. The effectiveness of the proposed numerical model is verified through a comparison with available experimental data in terms of ballistic performance and damage morphology. The effects of projectile shape, impact angle, and pre-stretching loading on the ballistic performance of 3DAWF are discussed. It is observed that 3DAWF demonstrates different impact resistance with different projectile shapes due to variations in the impact area and damage mechanism. The friction generated by projectile sliding plays a significant role in dissipating projectile kinetic energy under oblique impact. Moreover, pre-stretching is found to enhance the ballistic limit and energy absorption of 3DAWF to a certain extent.

Effect of Z-binding depths on the ballistic performance of 3D woven through-the-thickness angle-interlock fabrics in a multiply system

Lightweight armor with excellent protection against ballistic impacts are pursued by researchers worldwide. This paper systematically investigates the effect of the Z-binding depths on the ballistic performance and failure mechanisms of para-aramid 3D fabrics. Two types of 3D woven through-the-thickness angle-interlock fabrics were designed and fabricated in comparison to the 2D plain weave fabric. The ballistic tests and finite element simulation analyses were carried out based on a similar areal density of 5.2 kg/m2 by layering up the fabrics. According to the experimental results, the variability and cumulative probability of penetration of the 20-P are higher than that of the 3D fabric systems, resulting in a 2.5% higher ballistic limit V50 of 8-5 TA than 20-P. Fabric plies failed abruptly in the 2D system, while the 3D system showed a progressive failure mode. The Z-warps, configure through the thickness of the fabric, result in the projectile tumbling and deviating from its original direction. A larger binding depth can help to prolong the defending process, which will mobilize more yarns to resist the projectile impact. The back-face deformation is well constrained by the 3D fabrics. Due to the fact that the designed 3D woven fabrics are more moldable than the plain weave, it could be potential candidates for the engineering design of female bullet-proof vest interlining.

Interfacial Modification and Bending Performance of 3D Orthogonal Woven Composites with Basalt Filament Yarns.

To improve their interfacial properties, 3D orthogonal woven fabrics with basalt filament yarns were modified with functionalized carboxylated carbon nanotubes (KH570-MWCNTs) and polydopamine (PDA). Fourier infrared spectroscopy (FT-IR) analysis and scanning electron microscopy (SEM) testing were used. It was demonstrated that both methods could successfully modify basalt fiber (BF) 3D woven fabrics. The 3D orthogonal woven composites (3DOWC) were produced with epoxy resin and 3D orthogonal woven fabrics as raw material by the VARTM molding process. The bending properties of the 3DOWC were tested and analyzed by experimental and finite element analysis methods. The results showed that the bending properties of the 3DOWC modified by KH570-MWCNTs and PDA were significantly improved, and the maximum bending loads were increased by 31.5% and 31.0%. The findings of the finite element simulation and the experiment results were in good agreement, and the simulation error value was 3.37%. The correctness of the finite element simulation results and the model's validity further reveal the material's damage situation and damage mechanism in the bending process.

Influences of clamping methods and weaving architectures on the ballistic performance of 3D orthogonal woven fabrics

The great interlaminar strength and designability of 3D woven fabrics have application prospects in personal protective armor. This research reports the influence of clamping methods and weaving architectures on the ballistic mechanism of 3D orthogonal through-the-thickness interlock woven fabric (3D OTT). The investigation of the fabric's energy absorption, back deformation, and damage morphology was conducted using a mesoscopic yarn-level full-size model developed by the finite element method (FEM). The numerical simulation results under 4-sides held were verified with ballistic experiments, and a good match was achieved. The clamping method had a substantial effect on the fabric's performance. Under Weft-sides held, its ballistic limiting velocity was approximated by 4-sides held, although it experienced the greatest out-of-plane displacement. The worst energy absorption was recorded for the Warp-sides held, while the Corner held demonstrated an entirely different failure mechanism. Further investigation on the influence of warp yarn patterns on the protective capability of 3D OTT under different clamping methods indicated that the structure had limited influence on the ballistic performance of multi-layer fabrics and that the fabric with higher flexibility was more sensitive to boundary conditions.

Optimization of Uniaxial Tensile Stress-Strain Response of 3D Angle Interlock Woven Fabric Composite using Weft Density and Draw-In Plan Variables

Currently, 2D woven composites are extensively incorporated into a variety of technical automotive body parts and protective body armor owing to their excellent fabric strength performance. However, there is still a lack of attempts to utilize 3D woven fabrics for the same technical application. Hence, it is vital to examine the fundamental tensile strength of woven fabric composite materials when determining their suitability for end-use applications. This study aimed to investigate the novel effects of two parameters on the uniaxial tensile strength of a high-tenacity polyester three-layer 3D angle interlock (3DAI) woven fabric composite, namely, weave drafting draw-in insertion and weave density. Four different drafting patterns were considered: pointed (DRW 1), broken (DRW 2), broken mirror (DRW 3), and straight (DRW 4), for weft density at 14 and 25 pick.cm-1. Samples of the 3DAI woven fabric reinforced with epoxy composite at different drafting patterns and weft density combinations were produced and tested. Consequently, the maximum tensile stress and strain were recorded in the woven fabric composite sample with DRW 4 and 25 pick.cm-1 at 113 MPa and 11%, respectively. The study shows that different weft densities and draw-in plan settings play a significant role in the tensile strength performance of the 3DAI woven composite.

Geometric Analysis of Three-Dimensional Woven Fabric with in-Plane Auxetic Behavior

Auxetic textiles are emerging as an enticing option for many advanced applications due to their unique deformation behavior under tensile loading. This study reports the geometrical analysis of three-dimensional (3D) auxetic woven structures based on semi-empirical equations. The 3D woven fabric was developed with a special geometrical arrangement of warp (multi-filament polyester), binding (polyester-wrapped polyurethane), and weft yarns (polyester-wrapped polyurethane) to achieve an auxetic effect. The auxetic geometry, the unit cell resembling a re-entrant hexagon, was modeled at the micro-level in terms of the yarn's parameters. The geometrical model was used to establish a relationship between the Poisson's ratio (PR) and the tensile strain when it was stretched along the warp direction. For validation of the model, the experimental results of the developed woven fabrics were correlated with the calculated results from the geometrical analysis. It was found that the calculated results were in good agreement with the experimental results. After experimental validation, the model was used to calculate and discuss critical parameters that affect the auxetic behavior of the structure. Thus, geometrical analysis is believed to be helpful in predicting the auxetic behavior of 3D woven fabrics with different structural parameters.

A novel method for design and simulation of 3D woven preform

Increasing demand for high-performance applications of composite materials requires an integral forming process for complex components. As a composite reinforcement, 3D (three-dimensional) woven fabric has advantages in producing near-net-shaped preforms. However, previous studies focused on plates with uniform thickness, which are often variable thicknesses or special-shaped parts in practical applications. Some structures are prepared by stitching and then formed in the mold, but this increases the fiber damage. This study proposes a fabric design method based on yarn movement. By controlling the movement direction and distance of each yarn, the warp path in the fabric can be designed, which cause the change of fabric structure and achieve the integrated forming of special-shaped preforms. Based on this method, a software package for the preforms design and simulation is developed, which can be used for various woven and 3D textiles to illustrate its versatility.

Bending property of novel 3D woven variable thickness composites: Experiment and finite element analysis

AbstractVariable thickness composites are essential engineering materials which have been used in various high‐performance products. However, the commonly used variable thickness composites are mainly lamination, which is prone to delamination and reduce the overall performance under load. To solve this problem, 3D woven fabrics with integrity and continuous variable thickness have been designed and weaved on ordinary looms using basalt yarns. The resin‐based variable thickness composites have been prepared by vacuum‐assisted resin transfer molding (VARTM) process, and two different laminated composites have been produced for comparison. Compared with the two kinds of laminations, the bending strength of the 3D woven variable thickness (3DWVT) composites is increased by 12.28% and 16.22% under positive load; 16.74% and 17.08% under negative load. Finally, the meso‐finite element simulation analysis of the bending performance of 3DWVT composites was carried out by using the meso‐finite element analysis (FEA), and the damage mechanism and failure mode were explored.

Multifunctional auxetic and honeycomb composites made of 3D woven carbon fibre preforms

Three dimensional (3D) woven composites started to find applications in various industrial sectors, mainly in aerospace and with a potential in automotive. 3D-woven fabrics can be architected to form complex and near-net-shape preforms ready for automated composites manufacturing. The 3D-woven honeycomb fabric is designed to include additional functionality into finished composites, such as positive and negative Poisson's ratios. In this study, complex honeycomb architectures were created using various weave designs to demonstrate the effects of auxetic behaviours when manufactured into a composite structure. A Staubli 3D-weaving system equipped with Jacquard UNIVAL 100 and creel of 3072 6 k carbon fibre tows were used to weave the designed honeycomb architecture. With the aid of hard polyester foam inserts, the 3D-woven fabrics were converted to honeycomb and auxetic preforms. These preforms were infused using epoxy resin to manufacture a set of honeycomb and auxetic composite structures. In comparison with the baseline honeycomb structure, it is proven that the developed auxetic composites exhibited negative Poisson’s ratio of − 2.86 and − 0.12 in the case of tensile and compression tests respectively.

Application of 3D-Woven Fabrics for Packaging Materials for Terminally Sterilized Medical Devices.

This research aimed to test a newly developed 3D fabric for use in a hospital sterilization unit as a packaging material. Two basic properties were tested: the efficiency of the microbial barrier, and the bursting strength of the woven fabric, determined with a steel ball. Material deformations caused by bursting are common in medical sterilization, as a consequence of the packaging of the medical tools needed in surgery. Six 3D-fabric samples were woven from the same warp, with three weft densities and in two different weaves. The weaving conditions and other construction characteristics of the fabrics were the same. To determine the effectiveness of the microbial barrier, bacterial endospores of an apathogenic species of the genus Bacillus, Geobacillus stearothermophilus and Bacillus atrophaeus, were used. Mechanical testing of the 3D-woven fabric, i.e., the bursting strength of the fabric using a steel ball, was carried out according to the standard method. The results showed the exceptional puncture strength of the woven fabrics and their formation of an effective microbial barrier, i.e., complete impermeability to microorganisms in five samples, which is the main condition for possible use as a packaging material in medical sterilization. Sample 3tp did not provide an effective microbial barrier and did not meet the basic requirements for use in medical sterilization.