Additive Manufacturing of Lattice-Reinforced Hybrid Armor Systems: Mechanical Response and Ballistic Validation

A growing demand for lightweight and modular systems has particularly encouraged the design of hybrid add-on panels, in which conventional protective layers are combined with novel compositions of energy-absorbing components. In this work, a ceramic–lattice–metallic armor concept was proposed and evaluated as protection against 7.62×54R mm B32 armor-piercing projectiles. The multilayer system consisted of a ceramic strike face, a metallic lattice core produced by laser powder bed fusion and a high-performance steel backing plate. To assess the role of the lattice, several topologies were fabricated and tested in static compression and tension. Their mechanical responses were then homogenized to provide input data for equivalent numerical models. Among the tested designs, the SplitP lattice showed the most favorable balance of energy absorption and stability under load, which indicated its suitability for integration in hybrid panels. Ballistic trials conducted according to STANAG 4569 level III demonstrated that the proposed configuration effectively fragmented the projectile, dissipated its energy, and maintained structural integrity. Microscopic observations of destroyed structures were used to reveal the prevailing failure mechanisms within the lattices and ceramic layers. In parallel, numerical analyses employing JC (Johnson-Cook) and JH-2 (Johnson-Holmquist II) constitutive models were carried out, showing close agreement with the experimental data and validating the adopted modeling strategy. Finally, numerical optimization of the composites composition was performed with the aim of reducing overall weight while considering the potential to achieve even higher levels of ballistic protection (III+). The study confirms that combining widely available materials with additively manufactured lattice structures can significantly improve the performance of modular armor systems. The multi-stage approach made it possible to define further directions of development.