3D Printing Scale-Type Protective Composite Textiles

This study explores the development of a 3D-printed scale-type protective composite textile using biomimetic design principles, inspired by the scale structure of pangolins. Unlike conventional weaving techniques, 3D printing enables precise control over scale geometry (8-12 mm hexagonal units), hierarchical arrangements, and thermoplastic polyurethane (TPU) filler gradients (10-20 wt%), achieving a record puncture resistance of 56.1 N against 12G needles. Aimed at enhancing personal protective equipment, the scale-structured fabric offers improved puncture resistance, flexibility, and breathability. A systematic investigation into different scale configurations, material types, and infill densities reveals the optimal balance between stability and energy absorption. The results indicate that low-fill TPU scales exhibit the best puncture resistance while maintaining sufficient flexibility and air permeability. The study demonstrates the potential of biomimetic 3D-printed textiles as an innovative solution for lightweight, customizable, and efficient PPE materials.