Title: Impact Resistance of Corrugated Composite Structures Incorporating Polyurethane for Ballistic Armor

Authors: Carlos Perez, Jack Bride, Eltahry Elghandour

DOI:

Abstract: Traditional ballistic armor technology includes ceramics or metallic plates paired with soft layers meant to disperse impact energy and mitigate blunt force trauma. While effective, these systems are often heavy and reduce user mobility. Emerging research targets composite structures as a viable, lightweight, alternative to conventional ballistic armor solutions. This study investigates the feasibility of corrugated carbon fiber-Kevlar composite back plates as an alternative to traditional ceramic ballistic back plates, as well as the effectiveness of thermoset polyurethane as an energy dampening layer. Corrugated laminates were fabricated by laying up pre-impregnated carbon fiber and Kevlar in an aluminum mold, with stacking sequence and thickness varied to optimize weight and plate profile. The laminates were cured using a heat press. Mechanical characterization of the samples was conducted through three-point bend tests on flat and corrugated specimens, as well as impact testing on flat specimens. Ballistic performance was evaluated by firing 9mm full metal jacket rounds from a Glock handgun at a distance of 1.5 m onto samples with varying stacking sequences, both with and without a 4mm polyurethane dampening layer and raw Kevlar face sheet. Survivability was assessed by examining the extent of back plate damage. Results indicate that the corrugated carbon fiberKevlar composite back plate demonstrates promising potential, offering a resilient and lightweight alternative to ceramic systems.

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Conference: SAMPE 2026

Publication Date: 2026/04/27

SKU: 97

Pages: 16

Price: $32.00