Scientists at the California Institute of Technology (Caltech) have developed polycatenated architected materials (PAMs), a new class of 3D-printed structures that mimic the properties of both solids and fluids. These materials, inspired by chain mail, are poised to transform military technology, offering significant potential for next-generation body armor. The ability of PAMs to adapt to varying stress conditions could provide soldiers with unprecedented protection against modern battlefield threats.
PAMs are constructed from interlinked rings and other shapes arranged in intricate three-dimensional lattices, enabling the material to behave like a liquid under certain stresses and as a solid under others. When subjected to shear forces, the material offers minimal resistance, effectively dissipating energy across its structure. Under compression, however, PAMs become rigid, providing a protective barrier. This duality allows for adaptable armor that can absorb and redistribute the energy from impacts, such as bullets, shrapnel, and blasts, while remaining flexible for ease of movement.
The military applications of PAMs extend beyond body armor. Due to their lightweight and customizable structure, these materials could be incorporated into helmets, vehicle armor, and protective shielding for uncrewed systems. The interlinked nature of the material allows for durability under repeated impacts, ensuring long-term reliability in combat situations. Additionally, PAMs’ energy-absorbing properties could reduce the risk of traumatic brain injuries (TBI) for soldiers wearing enhanced helmets.
The unique behavior of PAMs also makes them well-suited for responding to emerging threats, including those posed by advanced weapons systems. Unlike traditional armor, which must be rigid to provide protection, PAMs offer a dynamic solution that adapts to different types of impact. For example, PAM-based body armor could absorb high-velocity ballistic impacts while remaining flexible and lightweight during regular troop movements. This could reduce fatigue and improve soldier performance in prolonged missions.
Caltech researchers envision even more advanced uses for PAMs, such as incorporating nanoscale designs for smart armor. By embedding sensors within the material, body armor could monitor environmental conditions, detect structural weaknesses, and even relay critical data to command centers. These features would provide soldiers with real-time feedback, enhancing situational awareness and safety in the field.
“The potential for PAMs in military applications is immense,” noted Professor Chiara Daraio, who led the research team. “From protecting individuals to fortifying vehicles, these materials can address the growing complexity of modern warfare.” The team’s experiments showed that PAMs can be tuned to respond differently based on specific battlefield requirements, allowing for armor that balances protection, flexibility, and weight.
With ongoing advancements in additive manufacturing, the military could produce PAM-based armor at scale, significantly lowering costs compared to traditional protective materials. Moreover, PAMs’ lightweight properties would reduce the logistical burden associated with transporting heavier equipment, providing an operational advantage in remote or austere environments.
