Conventional metallic or fiber-reinforced protective systems are often heavy, rigid, and costly. The ArMorph project aims to combine the high hardness and durability of ceramic materials with the low weight and shaping flexibility of fiber composites. This will enable even geometrically complex surfaces and structures to be protected efficiently in the future – ranging from ergonomic body armor elements and special-purpose protective vehicles to critical infrastructure and mobile systems.

At the heart of the concept are lightweight, three-dimensionally interlocking ceramic building blocks. These are combined with a flexible, multi-layer backing and elastic adhesive systems to form an adaptable protective composite. The segmented structure facilitates repairs and recycling.

Four Fraunhofer institutes are pooling their core competencies

Fraunhofer ICT is working on flexible polymer-fiber backings. Fraunhofer IKTS uses modeling to develop self-locking ceramic components and their optimal geometry. Fraunhofer IGP is developing elastic adhesive systems and scalable manufacturing processes for large-format components. Fraunhofer EMI is responsible for simulation-based design and ballistic testing.

Planned demonstrators include a flexibly adaptable protective vest element in protection class SK4 with a weight per unit area of less than 35 kg/m², as well as a complex-shaped segment for special-purpose vehicles in protection class VR7. This segment is expected to be significantly lighter than a comparable solution made of armored steel.

With ArMorph, the participating institutes aim to strengthen Europe’s technological leadership in the growing market for ballistic protection materials.

The project runs from March 1, 2025, through February 28, 2029, and is funded with approximately 3.5 million euros.