Intralayer-Hybrid Woven Lightweight Structural Composites for Impact-Resistant Protective Helmets

Objective

Fiber-reinforced composite helmet shells offer enhanced resistance to dynamic impacts compared to thermoplastic alternatives. However, conventional manufacturing relies on stacking fabric layers, which leads to a heavier structure, higher costs, a persistent material footprint, and susceptibility to delamination. This research addresses the global demand for sustainable protective composites through INTRACHEL, which aims to develop intralayer hybrid woven composite shells for protective helmets by enhancing mechanical performance while reducing weight, cost, and environmental impact. Aligned with the EU Green Deal, global sustainability goals, and Vision Zero, the project aims to replace energy-intensive synthetic materials with bio-based, sustainable, and protective composites. It focuses on combining natural and synthetic reinforcement to develop energy-efficient composites, while incorporating bio-based nanofillers to improve fiber-matrix bonding and minimize delamination risks. The work plan involves the development of intralayer hybrid fabrics by combining natural and high-performance fibers within optimized weave architectures. Spanning 24 months, the project will encompass fabric development, structural optimization, interlaminar and dynamic impact strength assessment, multiscale modeling, and regulatory validation, culminating in lightweight helmet shells with performance and sustainability metrics. My doctoral research in structural composites and experience at Steelbird Helmets in protective technology affirms my capability to deliver this project. This fellowship will strengthen my expertise in sustainable protective composites under Prof. Mishra’s mentorship at CZU, leveraging their advanced facilities and industrial partnerships to build interdisciplinary skills, gain exposure to product development and certification workflows, and position me for future EU projects, industry R&D roles, and faculty positions.