This paper presents a synthesis of failures of aramid fibers used in protective systems, with the help of SEM images obtained from three types of samples (panels made of fabrics with aramid fibers) tested against bullets, knives and spikes. This investigation is useful when using a step-by-step magnification and even macro photos in order to explain the mechanical failures of fibers. Several types of failure mechanisms (shear and tensile break, local bending, debonding from the matrix, fibrillation, local necking, etc.) were detected and discussed. Almost all of these failure mechanisms are present, with different densities of occurrence, in the studied panels made of aramid fibers. The description of failure mechanisms had to be conducted following the test conditions accurately. Failure mechanisms of aramid fibers are particularly relevant due to their specific molecular chains making them adequate for applications like ballistic and bladed weapon attacks.

Three-dimensional printed polymers produced using Fused Deposition Modelling (FDM) exhibit directional microstructures resulting from filament paths, layer interfaces, and cellular infill, leading to mechanical and tribological responses distinct from those of homogeneous bulk materials. This study presents a comparative tribomechanical evaluation of polypropylene (PP) bulk inserts and 3D-printed polyethylene terephthalate glycol (PETG) inserts with a 30% hexagonal infill, relevant for robotic gripping applications. Progressive scratch tests were performed under loads from 5 to 100 N (150 N for PP), and profilometry was applied to quantify groove morphology, ridge formation, and displaced-volume ratios. An elasto-plastic conical indentation model was used to derive indentation pressures and elastic–plastic transition radii from groove geometry. The PETG inserts exhibited heterogeneous groove depth, intermittent ridge tearing, and friction fluctuations associated with the internal infill structure, consistent with previous findings on anisotropy and architecture-dependent behaviour in additively manufactured polymers. In contrast, bulk PP demonstrated smoother friction profiles and more stable plastic flow under increasing loads. Two functional indices—specific frictional work and ridge-to-trace volumetric ratio—are introduced to support material selection for robotic gripping systems. The results show that local contact mechanics in 3D-printed inserts are governed by print-induced structural features and can be effectively evaluated through a scratch-based elasto-plastic analysis. The methods and results presented in this work support the rational selection and design of polymer inserts for robotic gripper fingertips. The proposed scratch-based elasto-plastic evaluation framework enables manufacturers and automation engineers to compare 3D-printed and conventional materials based on friction stability, wear response, and deformation resistance. This approach can be directly applied to optimise gripping performance in industrial handling, packaging, and collaborative robotics.