Preparation of Composite Panels Using Pultruded Tubes Based on a Two‐Step Molding Process and Their Impact Resistance Properties

ABSTRACT This study proposes a two‐step molding process for pultruded profiles, designing three types of composite panels: non‐woven, intralayer woven, and interlayer woven structures, and subjecting them to low‐velocity impact testing. The experimental results indicate that the non‐woven composite panel is prone to interlayer damage and resin failure under low‐velocity impacts, leading to the separation of pultruded tubes. The intralayer woven structure effectively mitigates impact damage, though the extent of damage increases with higher impact energy. In contrast, the interlayer woven structure more effectively transfers impact energy, reducing interlayer damage and exhibiting a distinctive “double‐lobe” damage morphology on the back face, demonstrating higher damage tolerance. Furthermore, sanding the pultruded tubes significantly enhances the interfacial strength between the tubes and resin, facilitating smoother transmission of impact stress waves within the specimen and reducing the likelihood of interlayer damage. This study provides theoretical support and practical guidance for the application of pultruded profiles in fields such as construction and transportation, particularly in scenarios requiring resistance to low‐velocity impacts, where composite panels prepared with interlayer woven structures and sanded pultruded tubes exhibit superior impact resistance.