Processing and Cutting High-Modulus Aramid (e.g., Kevlar 49, Twaron HM): Challenges and Recommendations

High-modulus aramid fibers, such as Kevlar 49 and Twaron HM, are known for their exceptional tensile strength, low elongation, and high stiffness. These fibers are primarily used in high-performance composite materials, such as in aerospace, automotive, and sports equipment industries.

Challenges in Processing

Processing aramid laminates is challenging due to their high tenacity and abrasion resistance. Traditional methods, such as circular saws or jigsaws, can damage the fibers and result in rough, frayed edges. Special care is required to avoid damaging the fibers while achieving clean cuts.

Recommended Cutting Methods

1. Special Scissors: Micro-serrated special scissors, such as those offered by R&G, are suitable for cutting fabrics.
2. Oscillating Saws: These types of saws are particularly suitable for cutting high-modulus aramid laminates as they provide uniform cutting without the risk of damaging the fibers or causing fraying. The non-rotating movement of the blade minimizes edge fraying and reduces the risk of delamination.
3. Waterjet Cutting: This method is especially effective for aramid fiber composites as it allows precise and clean cuts without damaging the fibers. The high-pressure water jet ensures a clean cut without fraying or delamination and can easily cut materials up to a thickness of about 10 mm.
4. Laser Cutting: For laminate thicknesses up to 10 mm, laser cutting is a good option as it enables precise cuts. However, the high temperatures generated during laser cutting can alter the material structure at the cut edges. For thicker laminates, waterjet cutting is generally preferred.
5. Mechanical Processing: When using circular saws or other rotating tools, the speeds should be reduced to protect the material and avoid excessive heat generation. However, these methods are less suitable and can result in damaged fibers, frayed edges, and delamination.
6. Drilling: Drills with sickle-shaped cutting edges are particularly suitable for drilling. The cutting design ensures less fraying of the fibers, resulting in cleaner cut edges.
   The special shape of the drill ensures better control and less material deformation, which is particularly important for precise drilling.