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Polymers and Polymer Composite Structures for Energy Absorption

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A special issue of Polymers (ISSN 2073-4360). This special issue belongs to the section "Polymer Applications".

Deadline for manuscript submissions: 30 April 2026 | Viewed by 7316

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Dr. Dariusz Pyka

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Department of Mechanics, Materials and Biomedical Engineering, Faculty of Mechanical Engineering, Wrocław University of Science and Technology, Smoluchowskiego 25, 50-372 Wrocław, Poland
Interests: composites; finite element method (FEM); smoothed particle hydrodynamics (SPH); armor; fracture mechanics; impact protection

Special Issue Information

Dear Colleagues,

The design of polymeric and composite structures with high energy absorption efficiency is crucial in modern industry, particularly in the automotive, aerospace, construction, and safety sectors.

In response to increasing demands for protection against impacts, vibrations, and other dynamic loads, the development of energy-absorbing materials has become a priority. Optimizing these structures involves designing the geometry and material configurations to maximize energy absorption capacity. Both experimental methods and advanced simulation techniques, such as FEM/SPH, are used for this purpose. The selection of appropriate materials is essential; polymers and composites are particularly attractive due to their flexibility, low weight, and the ability to modify their mechanical properties. Additives such as carbon, glass, or aramid fibers, as well as ceramic and metallic reinforcements, enhance their energy-damping properties. Three-dimensional printing technologies enable the creation of complex geometries with controlled pore arrangements that effectively absorb energy while remaining lightweight. These innovative materials find applications in automotive components, aerospace structures, seismic dampers in buildings, and protective gear. These technologies contribute to improved safety, reduced weight, and increased durability of structures under dynamic loading conditions.

Dr. Dariusz Pyka
Guest Editor

Manuscript Submission Information

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Keywords

energy absorption efficiency
composite structures
polymeric structures
impact protection
vibrations
energy-absorbing materials
material configurations
experimental methods
simulation techniques
protective gear

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Published Papers (5 papers)

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Research

21 pages, 5907 KB

Open AccessArticle

Attenuation Impact on Acoustic Emission Signal Parameters in Damage Mechanisms Characterization of Composite Rebars

by Paweł Zielonka, Michał Smolnicki, Szymon Duda and Grzegorz Lesiuk

Polymers 2025, 17(23), 3128; https://doi.org/10.3390/polym17233128 - 25 Nov 2025

Viewed by 830

Abstract

Composite materials have been extensively used across numerous industries due to their exceptional specific strength and corrosive resistance. However, ensuring their mechanical performance and structural integrity remains a critical challenge. This study provides an in-depth investigation into the damage mechanisms occurring in composite rebars manufactured via a modified pultrusion process, with a special emphasis on carbon, glass, and hybrid continuous fiber-reinforced polymers with epoxy resin matrix subjected to static tensile loading. To reveal the damage development, the acoustic emission (AE) technique was employed. Given the inherent complexity of composite microstructures, multiple failure modes can occur simultaneously, often masked by background noise and attenuation effects. Therefore, the core objective of this research is to evaluate and quantify the influence of acoustic attenuation on damage assessment in composite materials. This study introduces an optimization approach to minimize discrepancies between signals captured by different sensors, thereby enhancing the reliability of AE data interpretation. Results reveal that attenuation is strongly dependent on signal travel distance, frequency spectrum, and sensor type. Importantly, a data correction methodology is proposed to mitigate these effects, improving the accuracy of damage detection. Among the analyzed AE parameters, the initial frequency emerged as the most reliable feature for identifying the origin of acoustic events within hybrid composite structures. This finding represents a significant step toward more precise, attenuation-compensated acoustic emission monitoring, offering improved insight into failure mechanisms and contributing to the development of smarter diagnostic tools for composite materials. Full article

(This article belongs to the Special Issue Polymers and Polymer Composite Structures for Energy Absorption)

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17 pages, 2877 KB

Open AccessArticle

Modal Analysis–Based Detection of Barely Visible Impact Damage in Carbon/Epoxy Overwraps of Type-IV Polymer-Lined Pressure Vessels

by Mirosław Bocian, Mikołaj Kazimierczak, Barbara Kmiecik, Marek Kryspin and Maciej Panek

Polymers 2025, 17(22), 3068; https://doi.org/10.3390/polym17223068 - 19 Nov 2025

Viewed by 676

Abstract

A vibration-based protocol is presented for identifying barely visible impact damage (BVID) in type-IV composite-overwrapped pressure vessels (COPVs). A 1 kJ hemispherical-tip strike was applied to a fully pressurized vessel, which was subsequently depressurized and characterized by free–free experimental modal analysis over a 168-point grid. The frequency response functions (FRFs) at the impact meridian exhibited distinct peaks near 3.70, 4.34, and 4.90 kHz with larger amplitudes and lower coherence than at the diametrically opposite meridian, indicating local circumferential stiffness loss. A detailed finite element model of the liner, bosses, and carbon/epoxy overwrap was updated by idealizing a cylindrical sub-volume with a 90% reduction in orthotropic stiffness. The pristine and “damaged” numerical modal sets agreed closely (mean frequency error < 2%), and for most of the first 60 modes, the diagonal Modal Assurance Criterion (MAC) remained ≥ 0.90. However, in several nearly degenerate circumferential mode pairs, the diagonal MAC dropped to 0.49–0.88 because the local asymmetry rotated the eigenvectors within a common subspace, showing that classical MAC alone cannot expose such early-stage defects. Radial displacement scan-lines provided the missing spatial resolution. Modes whose antinodal regions intersect the dent showed pronounced local amplitude bulges and slight angular shifts in the peak toward the impact site, whereas modes with a nodal line across the damage were virtually unchanged. The combined use of FRF asymmetry, MAC screening, and scan-line deformation profiling localized the impact to the correct circumferential sector with centimeter-scale resolution along the scan ring, yielding predictive signatures for rapid, non-pressurized in situ assessment of impacted COPVs after depressurization. Full article

(This article belongs to the Special Issue Polymers and Polymer Composite Structures for Energy Absorption)

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20 pages, 10557 KB

Open AccessArticle

Microstructural and Impact Resistance Optimization of Concrete Composites with Waste-Based Aggregate Substitutions

by Maksymilian Stępczak, Mikołaj Kazimierczak, Maciej Roszak, Adam Kurzawa and Krzysztof Jamroziak

Polymers 2025, 17(19), 2574; https://doi.org/10.3390/polym17192574 - 23 Sep 2025

Cited by 1 | Viewed by 864

Abstract

In the context of growing challenges related to the safety and durability of civil infrastructure, the demand for concrete composites capable of withstanding dynamic and impact loading is steadily increasing. Conventional concrete, owing to its brittle nature and limited energy absorption capacity, does not always meet the performance requirements imposed on protective structures. The construction sector’s substantial contribution to CO₂ emissions further underscores the need for environmentally responsible solutions. This study therefore explores the effects of partially replacing natural aggregate with waste-derived constituents such as SBR rubber granulate, copper slag, polypropylene and glass granulate on the mechanical properties and impact resistance of concrete. Scanning electron microscopy (SEM) and stereoscopic microscopy were used to characterize the additives’ geometry and interfacial bond quality, providing deeper insight into cement paste–aggregate interactions. Compressive testing confirmed that introducing the recycled components does not preclude meeting essential strength criteria, whereas impact experiments revealed pronounced differences in failure mode, crack propagation, and the specimen’s ability to dissipate kinetic energy. The experimental program was complemented by a life cycle assessment (LCA) that quantitatively estimated the CO₂ emissions associated with producing each mixture. The findings demonstrate that judiciously selected waste materials can reduce the consumption of virgin resources, enhance concrete functionality, and improve their protective performance, thereby advancing the principles of a circular economy. Full article

(This article belongs to the Special Issue Polymers and Polymer Composite Structures for Energy Absorption)

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10 pages, 7568 KB

Open AccessArticle

The Influence of Fiber Tension During Filament Winding on the Modal Parameters of Composite Pressure Vessels

by Aleksander Kmiecik and Maciej Panek

Polymers 2025, 17(15), 2071; https://doi.org/10.3390/polym17152071 - 29 Jul 2025

Cited by 1 | Viewed by 1472

Abstract

The aim of this paper is the investigation of changes in modal parameters of composite pressure vessel structures with different prestress states realized by varying fiber tension. Two series of vessels was manufactured and examined with different wound tensions, the first—3 N and second—80 N, respectively. Other technological factors, such as the type and weight of carbon fiber used, as well as liner type, were kept constant. The vessels were examined with internal pressure equal to atmospheric and without pressure fittings. The modal tests were performed on storage tanks suspended on an elastic cord in the horizontal orientation to prevent the structure from being disturbed by vibrations. The examinations were focused only on the cylindrical part of the vessels. Based on modal analysis, parameters such as natural frequencies, dampings and modal shapes were determined. Research results indicate clear changes in natural frequencies and damping coefficients between the two investigated prestress states. It is interesting that natural frequencies for bending modes are higher in the case of structures with high fiber tension, while in the case of other vibration forms, the natural frequencies have smaller values in comparison with the first series. Full article

(This article belongs to the Special Issue Polymers and Polymer Composite Structures for Energy Absorption)

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26 pages, 28205 KB

Open AccessArticle

Enhanced Mechanical Performance of Resin-Infused 3D-Printed Polymer Lattices

by Jakub J. Słowiński, Maciej Roszak, Mikołaj Kazimierczak, Grzegorz Skrzypczak and Maksymilian Stępczak

Polymers 2025, 17(8), 1028; https://doi.org/10.3390/polym17081028 - 10 Apr 2025

Cited by 6 | Viewed by 2587

Abstract

Fused deposition modelling (FDM) technology provides a flexible and cost-effective solution for the manufacture of polymer components, enabling the precise design of structures and the incorporation of a variety of composite materials. Its development is confirmed by numerous studies on fibre reinforcements (e.g., GFRP and CF) and thermosetting resin modifications, resulting in improved impact strength and fracture toughness and increased thermal stability of products. The final mechanical properties are significantly influenced by processing parameters (e.g., fill density, layer height, and printing speed) and internal geometry (e.g., lattice structures), which can be further optimised by numerical analyses using constitutive models such as the Johnson–Cook model. The focus of the study presented here is on the fabrication of composites from FDM dies filled with F8 polyurethane resin. Filaments, including PETG carbon and PETG, were tested for potential applications with the resin. A static compression test, supported by numerical analysis using the Johnson–Cook model, was carried out to identify key mechanical characteristics and to predict the material’s behaviour under different loading conditions. The results indicate that these structures exhibit numerous potential delamination planes and voids between filament paths, leading to relatively low maximum stress values (σ_m ≈ 2.5–3 MPa). However, the impregnation with polyurethane resin significantly enhances these properties by bonding the layers and filling the pores, resulting in a more homogeneous and stronger composite. Additionally, numerical simulations effectively captured key aspects of structural behaviour, identifying critical stress concentration areas, particularly along the side walls and in regions forming triangular stress zones. These findings provide valuable insights into the potential of resin-filled FDM structures in engineering applications, demonstrating their improved performance over purely printed samples. Full article

(This article belongs to the Special Issue Polymers and Polymer Composite Structures for Energy Absorption)

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