Known for its strength-to-weight ratio, Kevlar EXO versatility and durability have exceeded the previous standards for protection, performance, and strength. Kevlar EXO, the next-gen aramid fibre, combines ballistic and thermal performance with peak flexibility and reduced weight. Requiring 50% less energy to bend and 50% less pressure on the body compared to traditional armour, it contours the body for increased comfort and mobility.

This leads to improved performance for military personnel and law enforcement officers who can now experience less fatigue. Kevlar EXO’s flame and temperature-resistant material (resisting extreme heat up to 500 °C) and ability to maintain the same level of protection after five years, make the perfect material for high stress environments.

The engineers behind Kevlar EXO partnered with the Hohenstein Institute to develop new testing methods for the fabric, simulating real-world movements and discomfort points including Lower Costal Bending test, Edge Pressure test and Double Curvature Compression tests.

Building on its success in soft armour, Kevlar EXO is expanding into hard armour applications, serving as a structural reinforcement in composite systems like ballistic plates and helmets. The Kevlar EXO material absorbs up to 2.5 times more energy while remaining 30-40% lighter, limiting crack propagation and trauma from high-velocity rounds while also enhancing performance.

The upcoming launch of Kevlar EXO’s hard armour line will mark a milestone for industry standards in ballistic protection and trauma performance. These innovations support the priority of decreasing weight loads for personnel, while enhancing both performance and survivability.

Kevlar EXO is already being integrated into plates for TYR Tactical, the leading global manufacturer of tactical gear and equipment for military and law enforcement. Additional trauma performance testing is underway with the UK’s Defence Science and Technology Laboratory (DSTL) to measure how Kevlar EXO reduces back-face deformation, minimises blunt force trauma and tracks how the body responds under impact.

At the Defense Textiles & Innovation Convention this November, Kevlar EXO will showcase its latest developments and host live demonstrations of how this next-gen fibre performs in body armour. Kevlar EXO continues to revolutionise the textiles industry in its ability to raise the bar for performance and protection across multiple industries. Applications for Kevlar EXO in aerospace, industrial safety and water sports are also being explored. The engineers behind the fabric are continuing to research the wide variety of possibilities and places where a lightweight, durable and versatile fabric can improve results.

Kevlar EXO website