Quantifying the influence of weave parameters on the pull-out resistance of functional shape memory alloy wires in multilayer weaves for active composites

The growing demand for functionalized fiber-reinforced plastics has intensified research on the robust integration of actuating elements such as Shape Memory Alloy (SMA) wires to enable adaptive structural behavior. While SMA-based actuation is well established, mechanical performance is fundamentally limited by the SMA-textile interface, particularly in force transmission zones. This study addresses the lack of systematic design rules for 3D multilayer woven structures by investigating three key parameters: deflection ( d ), horizontal length ( h ) and vertical length ( v ), Utilizing a three-stage experimental design, d and v were identified as the dominant factors governing friction according to Capstan’s Law. Quantitatively, while insufficient embedding reached only 33–57 N, optimized configurations achieved consistent forces of 100–110 N. A structural threshold at d ≥ 4, corresponding to a “Critical Length” ( L c ) where binding strength exceeds the wire’s tensile capacity (∼108 N), resulting in wire fracture rather than extraction. Furthermore, central vertical positioning within the 3D structure was found to be essential to maintain the necessary counter-pressure for stable friction. These findings provide validated quantitative design guidelines for SMA integration, ensuring that structural binding withstands maximum actuation forces. This work significantly enhances the functional reliability and durability of adaptive systems.