The paper investigates the processing technology and mechanical properties of a novel type of 3D‐braided composite material, named as one‐carry‐two full five directional braided composite (1C2 3DF5d). The material differs from the conventional 3D‐braided composites by doubling the number of braiding yarns in the cross section. This unique yarn architecture is achieved by the introduction of a novel yarn carrier path planning method and side (support) gear design on a rotary braiding machine. The proposed braiding machine and the preform manufacturing process are first compared to the established approaches in textile composite industry, namely the one‐carry‐one (1C1) method under a new classification scheme. A parametric representative unit cell (RUC) model of the new material is then established which reveals that the cross‐section area is increased more than 58% compared to 1C1 braiding materials under the same braiding angle, and the fiber volume fraction is lower by 14%–16%. Damage propagation of the material under tensile and compressive loading conditions are simulated using finite element method based on the 3‐d Hashin failure criterion. The longitudinal stiffness and strength of 1C2 3DF5d are compared to 1C1 3DF5d composites and demonstrate a reduction of more than 20% for both due to the lower fiber volume fractions. However, the loading carrying capability of the material is increased by 10%–20% due to the increased cross section area. The technology may serve as a new way to manufacture 3D‐braided materials with large cross section and high load‐ carrying capabilities.

本文研究了一种新型的3D编织复合材料的加工技术和力学性能，该材料被称为“一带二全五向编织复合材料（1C2 3DF5d）”。这种材料与传统的3D编织复合材料的不同之处在于，其横截面中的编织纱线数量增加了一倍。通过在旋转编织机上引入新颖的纱架路径规划方法和侧边（支撑）角轮设计可以实现这种独特的纱结构。首先将所述的编织机和预制体制造工艺与纺织复合材料行业中已建立的方法，即在新的分类方案下被称为一带一（1C1）方法，进行比较。然后，建立了新材料的参数化代表性单胞（RUC）模型，该模型显示在相同的编织角度下，与1C1编织材料相比，预制体横截面积增加了58％以上，并且纤维体积分数降低了14 ％–16​​％。基于3-d Hashin破坏准则，使用有限元方法模拟了材料在拉伸和压缩载荷条件下的损伤传播。将1C2 3DF5d的纵向刚度和强度与1C1 3DF5d复合材料进行了比较，并显示出由于纤维体积分数较低，两者的降低幅度均超过20％。但是，由于横截面积的增加，材料的总承载能力提高了10％–20％。该技术可能成为制造具有大横截面和高承载能力的3D编织材料的新方法。