With the development of technology, fibers and textiles are no longer exclusive for the use of clothing and decoration. Protective products made of high-strength and high-modulus fibers have been commonly used in different fields. When exceeding the service life, the protective products also need to be replaced. This study proposes a highly efficient recycling and manufacturing design to create more added values for the waste materials. With a premise of minimized damage to fibers, the recycled selvage made of high strength PET fibers are reclaimed to yield high performance staple fibers at a low production cost. A large amount of recycled fibers are made into matrices with an attempt to decrease the consumption of new materials, while the combination of diverse plain woven fabrics reinforces hybrid-fabric fibrous planks. First, with the aid of machines, recycled high strength PET fibers are processed into staple fibers. Using a nonwoven process, low melting point polyester (LMPET) fibers and PET staple fibers are made into PET matrices. Next, the matrices and different woven fabrics are combined in order to form hybrid-fabric fibrous planks. The test results indicate that both of the PET matrices and fibrous planks have good mechanical properties. In particular, the fibrous planks yield diverse stab resistances from nonwoven and woven fabrics, and thus have greater stab performance.

In this study, high resilience polyester fibers and low melting point polyester (LMPET) fibers are blended at varying ratios in order to form buffering composite nonwoven fabrics. Next, the employment of hot pressing enables the combination of the fabrics and elastic polymer films. The mechanical and buffering properties of the composites are evaluated in terms of the blending ratio and the thickness of the composites. As per the interface observation and the results of the peel test, the nonwoven fabrics and polymer films are firmly bonded. The tensile test results indicate that when there is more content of LMPET fibers, the reinforcement to the composites is greater. Conversely, the puncture test results indicate that the LMPET‐fiber‐free composites possess 1.4 times higher puncture resistance. Based on the results of the hammer rebound and compression recovery tests, a greater thickness provides the composites with better buffering efficacy.