This paper investigates the penetration and energy absorption mechanisms of ultra-high-molecular-weight polyethylene plain weaves with different fabric properties. Impact tests along with finite element (FE) analysis were used to study the impact response of the fabrics. In this research, the impacting projectile did not cause any fiber or yarn failure on the samples. It was found that structural parameters determine the yarn pull-out behavior and the softness of the resultant fabrics. Fabrics formed by loosely interlaced yarns tend to exhibit higher softness and less resistance against yarn pull-out. When the projectile velocity is not sufficient to initiate yarn pull-out, material softness determines the depth of the backface signature on the clay witness. This trend is more pronounced in a multi-ply fabric system than in a single-ply system; when yarn pull-out occurs, the projectile-slowing mechanism depends on the frictional force between the warp and weft yarns. Therefore, fabric softness becomes less important, and the yarn pull-out behavior of the fabric plays a predominant role in energy absorption. FE prediction showed that tightly woven fabrics exhibit a larger area of stress distribution and material deformation than those with severe yarn pull-out and, consequently, these tight fabrics tend to absorb more kinetic energy and sustain higher impact load from a projectile.
