Structure forming and characterization of compressive properties of three-dimensional woven fabric composites based on e-entrant honeycomb structure

Three-dimensional (3D) woven fabric composites with re-entrant honeycomb structures (3DRHWC) exhibit lightweight, low-density and compressively resilient properties due to their negative Poisson’s ratio (NPR) effect. This study systematically investigates 3DRHWC through an integrated approach combining theoretical modeling, experimental characterization and finite element analysis. The refined analytical model demonstrates excellent agreement with both experimental and numerical results. Key findings reveal that 3DRHWC displays unique four-stage compression behavior: (1) a concave elastic region, (2) a stress plateau, (3) a platform enhancement zone initiating at ∼46% strain and (4) delayed densification (onset strains: 52–62%, angle-dependent). The re-entrant angle (θ) critically governs mechanical performance: larger angles (e.g. 70°) elevate pre-densification stress and prolong the plateau region compared to smaller angles (e.g. 30°). Notably, while θ strongly influences both compressive strength and NPR magnitude, matrix materials primarily affect stress scaling without altering fundamental deformation mechanisms. These insights provide a scientific foundation for designing NPR-enhanced textile composites in impact-resistant applications such as aerospace and personal protection.