Work

Development of transparent polymer armour based on high-strength polyethylene films

Year: 2025

Type: article

Abstract: Current impact-resistant and anti-ballistic composite materials for personal protection are typically either non-transparent - such as those made from ultra-high molecular weight polyethylene (UHMWPE) and aramid fibres - or transparent materials like laminated glass, which have limited formability, or plastic sheets like polycarbonate (PC) or polymethyl methacrylate (PMMA), which offer relatively low mechanical strength. This paper introduces a method to enhance the impact and ballistic resistance of PC and PMMA laminates - commonly used in protective visors - by integrating oriented, high-strength, transparent high-density polyethylene (HDPE) films. These films, as strong as steel yet significantly lighter, are produced via cast-film extrusion followed by controlled drawing and stretching to create a highly oriented polymer structure. Exhibiting over 90% light transmittance and tensile strength up to 15 times greater than PC or PMMA, these transparent HDPE films substantially improved the performance of hybridised polymer laminates. This advancement represents a significant step toward developing lightweight, impact-resistant, transparent armour and protective equipment for use in law enforcement, public safety, military, and recreational settings.

Source: Journal of Materials Research and Technology

DOI: 10.1016/j.jmrt.2025.08.192

Authors: Muhammad Rehan Asghar Bhatti, Jaipal Gupta, Samson Gnanadass, Colin John Robinson, Ton Peijs

Institutions: Queen Mary University of London, University of the West of England, University of Warwick

Language: English

Topic: Polymer crystallization and properties

Subfield: Polymers and Plastics

Field: Materials Science

Domain: Physical Sciences

Open Access status: gold

Estimated APC paid: $1,640

Funders: University of Warwick, Defence Science and Technology Laboratory, Defence and Security Accelerator