Fabrication and constituent materials evaluation of metal mesh-GF/PP hybrid tubes for lightweight structural applications

Metal mesh-reinforced thermoplastic composites have emerged as promising candidates for lightweight, energy-absorbing structures in aerospace applications. However, their mechanical performance is highly sensitive to fabrication parameters such as winding angle, layer sequence, and forming pressure. In this study, a hybrid tube structure composed of GF/PP prepreg and stainless-steel mesh was fabricated using a manual winding process, aiming to optimize the structural design and processing conditions. A custom-built winding platform was used to ensure stable operation, and the effects of lay-up configuration and compaction pressure were investigated. The [45°/-45°/metal mesh/-45°/45°] lay-up with 40 N pressure offered superior surface finish and mechanical balance through improved interfacial bonding. Mechanical tests, including tensile, compressive, and shear experiments were conducted according to ASTM standards. The GF/PP composite exhibited high tensile strength along the fiber direction and stable shear resistance, while the metal mesh demonstrated elastic–plastic behavior under uniaxial loading. The results confirm the feasibility of the proposed process and lay-up strategy, providing a basis for structural design and simulation of high-performance hybrid components.