Abstract
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.
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