Ballistic performance of multi-layer PC/PU/PMMA transparent armor: experimental and numerical investigation

The increasing demand for lightweight, transparent ballistic protection has driven the development of advanced multilayer armor systems for civilian and military applications. Transparent armor must provide high impact resistance, maintain optical clarity, and effectively absorb projectile energy while minimizing structural damage. This study investigates the ballistic performance of a novel multilayer transparent armor system composed of polycarbonate (PC), polyurethane (PU), and polymethyl methacrylate (PMMA) using both experimental testing and numerical simulations in ANSYS Workbench LS-DYNA. Finite element analysis was conducted to examine the dynamic response of the armor subjected to 9 mm projectile impact. Experimental validation was performed using armor panels measuring 350 × 500 mm 2 positioned at a firing distance of 5 m. Post-impact analyses were carried out to evaluate penetration resistance, damage evolution, and failure mechanisms. The combined numerical and experimental results reveal that polycarbonate exhibits excellent impact resistance due to its high toughness and ductility, whereas polyurethane and PMMA enhance energy dissipation and reduce stress transmission through their layered structures. The proposed multilayer configuration successfully resisted projectile penetration, exhibited only localized damage, and maintained good optical transparency after repeated impacts. The close agreement between simulation and experimental observations validates the finite element model and confirms the effectiveness of the proposed multilayer polymeric armor system. These findings demonstrate the potential of lightweight, transparent, polymer-based armor for applications such as vehicle glazing, security barriers, and personal protective equipment that require both high ballistic resistance and optical transparency.