Optimization of fibre-reinforced composites for lightweight ballistic body armour

This study presents an innovative approach to optimizing fiber-reinforced composite materials for ballistic body armor, enhancing protection against 7.62 mm AK-47 rifle bullets. Through finite element analysis (FEA), the mechanical responses of Kevlar/alumina and Dyneema/epoxy composites were investigated under ballistic impact conditions. FEA results indicate that Dyneema/epoxy could provide a significant reduction in areal density (≈56.9 %) and an improved energy-absorption capacity (≈55.1 %) relative to the Kevlar/alumina system considered here; these values are derived from numerical simulations validated against literature data and should be confirmed with targeted ballistic experiments. The novelty of this research lies in the comparative investigation and optimization of next-generation lightweight composite systems, including Dyneema/epoxy, Kevlar/alumina vests used by Ethiopian military forces. This is one of the first studies to integrate finite element simulations, and damage mechanics (Hashin criteria) to quantify the ballistic performance of these advanced composites under real-world threat levels. Moreover, this research introduces a new paradigm in ballistic armor design by systematically correlating weight efficiency, damage resilience, and stress–strain behavior in multi-layered composite laminates. The study highlights the cost-effectiveness and potential of Dyneema/epoxy to redefine ballistic protection by balancing weight, efficiency, durability, and impact resistance. These findings establish Dyneema/epoxy as a next-generation material for advanced body armor applications.