Breathable and impact-resistant shear thickening gel based three-dimensional woven fabric composites constructed by an efficient weaving strategy for wearable protective equipment

External low-velocity impacts (LVI) inevitably endanger human body health, yet attaining wear comfort and impact resistance simultaneously in protective equipment is challenging. Herein, flock-reinforced shear thickening gel (FRSTG) was demonstrated to display exceptional shear thickening behavior above the critical shear frequency (80.5 Hz). Three-dimensional (3D) shaped woven fabrics with folded structures were efficiently realized on a modified loom assembled with double warp beams and asynchronous self-reversal let-off systems, then 3D FRSTG/woven fabric composites were manufactured through a facile inclusion procedure. The “sizing effect” of FRSTG on the yarns resulted in enhanced mechanical properties of the composites. Attributed to the folded structures, the composites exhibited desired flexibility and innovatively achieved breathability (79.473 mm/s). They also performed responsive LVI resistance owing to the shear thickening effect of FRSTG and structural advantages of 3D shaped woven fabric. Furthermore, wearable protective applications based on those composites were evidenced to integrate breathability and LVI resistance.