Weaving Architecture‐Driven Changes in Mechanical, Vibration and Acoustic Behaviour of Metal Mesh Embedded Natural Fiber Hybrid Composite

ABSTRACT This research aims to develop an innovative fiber‐reinforced polymer composite that integrates the advantages of flax fibers using a unique flax yarn‐weaving technique on a stainless‐steel 304 wire mesh (FSS 304). Although flax fibers offer advantageous reinforcement characteristics, their intrinsic mechanical constraints have prompted the investigation of hybrid composite designs with enhanced performance. This paper describes the fabrication and characterization of a novel hybrid composite that uses the synergistic reimbursement of FSS 304 and flax fibers, yielding a lightweight yet durable material appropriate for diverse engineering applications. Four distinct configurations (F30°, F45°, F60°, and F90°) were fabricated to examine the effects of the reinforcement orientation. The experimental findings indicate that the integration of FSS 304 markedly improves the composite hardness (F90°‐23.8 VHN), impact resistance (F30°—8.4 J), flexural strength (F90°—106.58 MPa), and tensile strength (F90°—49.2 MPa). Furthermore, acoustic analysis demonstrated that the fiber orientation substantially influences sound absorption and transmission loss, with the F90° orientation exhibiting the most effective noise reduction, especially in the 600–2000 Hz frequency range. The composite F45°‐oriented FSS 304 enhanced the natural frequency by 22%. Microstructural analysis by SEM and EDX confirmed the elemental composition. The resulting lightweight and eco‐friendly composites exhibit enhanced performance for diverse engineering applications.