Despite the wide use of three‐dimensional (3D) woven composites in different applications, their production is often costly. This study explores cost‐effective 3D orthogonal woven polymer composites to enhance mechanical performance. Four 3D composite variants, each incorporating different volumes of z‐binders (copper wires or glass fibers), were compared to a 2D woven composite. All composites were produced using a simple, economical hand lay‐up method. Wear resistance, in‐plane shear strength, and impact strength were assessed. Results indicated that all 3D composites surpassed the 2D composite in impact strength, especially those reinforced with glass fiber z‐binders. The single glass fiber z‐binder composite exhibited the highest impact strength increase (20.6%). Most 3D composites showed slightly reduced in‐plane shear strength compared to the 2D composite, with the smallest decrease (1.68%) observed in specimens with a small copper z‐binder. Notably, all 3D composites demonstrated superior wear resistance to 2D counterparts under various loads. Glass fiber z‐binder reinforcements outperformed copper z‐binders, with double fiber z‐binders yielding the maximum wear resistance enhancement. These findings underscore the potential of 3D woven composites for applications demanding high impact and wear resistance, such as automotive, structural components, and sports equipment.Highlights
3D woven composites are widely used in various engineering applications.
Limited studies explore the in‐plane shear and wear behavior of 3D composites.
Copper and glass fiber z‐binders were used in manufacturing 3D woven composites.
The used hand lay‐up method reduces manufacturing costs.
3D woven composites improve impact and wear resistance compared to 2D ones.