Geometrical modeling and experimental validation of 3D woven honeycomb fabric for lightweight aircrew helmet liner manufacturing

This research focused on the development of a honeycomb fabric by predicting the areal density suitable for aircrew helmet liner. The aim was to fulfill the requirements for the lightweight and mechanical properties of composite liner. The model was based on the structural characteristics of the preform, including the weave design and geometric parameters. The predicted areal density, based on varying yarn linear density and the number of picks in the free and bonded wall, was compared to experimental results and showed good agreement. A geometric model was derived to predict the areal density of 3D woven honeycomb preforms for producing the composite liner of aircrew helmet. The model was validated using experimental data from a variety of 3D woven honeycomb preforms, showing that it accurately predicts the areal density and can be used as a tool to design 3D woven honeycomb preforms for advanced composites. [Graphical Abstract]