ABSTRACT In this study, structural optimization through axial yarn replacement and layered braiding was conducted to enhance yarn utilization efficiency and axial compressive strength. In the axial yarn replacement configuration, the primary function of the braiding yarns shifted from load‐bearing to providing constraint. The layered braiding method effectively mitigated the undulation of axial yarns. Additionally, finite element analysis results revealed that exchanging specific braiding yarns in the layered braiding process could enhance the constraint on axial yarns, although it led to premature interfacial and axial yarn failure. Significantly, compressive strength and yarn utilization efficiency were not necessarily positively correlated with the proportion of axial yarn unless the constraint provided by the braiding yarns is sufficient. Compared to the conventional composite, the compressive strength and yarn utilization efficiency of the optimized composite increased by an average of 152.86% and 114.96%, respectively. Noteworthily, the axial yarn replacement can markedly decrease the proportion of braiding yarn and the number of required carriers during braiding, thereby lowering the complexity of the coordinated movement of numerous carriers in a confined space of braiding equipment. This is of great significance for promoting its industrial application.
Wang et al. (2026) studied this question.