Study on the mechanism and performance of 3D-printed PLA/epoxy composite for stab resistance

Purpose Stab-resistant body armor (SRBA) is used to protect the body from sharp knives. However, most SRBA materials currently have the disadvantages of large weight and thickness. This paper aims to prepare lightweight and high-performance SRBA by 3D printing truss structure and resin-filling method. Design/methodology/approach The stab resistance truss structure was prepared by the fused deposition modeling method, and the composite structure was formed after filling with resin for dynamic and quasi-static stab tests. The optimized structural plate can meet the standard GA68-2019. Digital image correlation technology was used to analyze the local strain changes during puncture. The puncture failure mode was summarized by the final failure morphologies. The explicit dynamics module in ANSYS Workbench was used to analyze the design of the overlapped structure stab resistance process in this paper. Findings The stab resistance performance of the 3D-printed structural plate is affected by the internal filling pattern. The stab resistance performance of 3D-printed structural parts was significantly improved after resin filling. The 50%-diamond-PLA-epoxy, with a thickness of only 5 mm was able to meet the stab resistance standard. Resins are used to increase the strength and hardness of the material but also to increase crack propagation and reduce the toughness of the material. The overlapping semicircular structure was inspired by the exoskeleton structure of the demon iron beetle, which improved the stab resistance between gaps. The truss structure can effectively disperse stress for toughening. The filled resin was reinforced by absorbing impact energy. Originality/value The 3D-printed resin-filled truss structure can be used to prepare high-performance stab resistance structural plates, which balance the toughness and strength of the overall structure and ultimately reduce the thickness and weight of the SRBA.