Carbon Nanotube-Woven Fabric Outperforms Kevlar in Strength

The innovative material is remarkably strong, capable of stopping bullets with a 1.8-millimeter-thick sheet, surpassing Kevlar and potentially setting a new standard for fabric strength.

Bulletproof vests functionality relies on dissipating the energy of projectiles through an intricate network of interconnected fibers. Kevlar’s composition consists of aramid fibers, which are polymers recognized for their exceptional strength. However, under extreme pressure, these chains can slip, which limits their protective capabilities.

For the last six years, Jin Chang and researchers from Peking University in China have focused on creating materials that outperform Kevlar and Dyneema, another renowned polyethylene fiber claimed to be the strongest fabric in the world.

“Extremely high dynamic strength and toughness are essential for textile materials used in impact protection applications,” notes Zhang. “This includes ballistic armor, vehicles, and aircraft.”

His team has pioneered a technique to align carbon nanotubes with aramid polymer chains to prevent molecular slippage. “Our new fiber surpasses all previously noted high-performance polymer fibers,” asserts Zhang. “Our fabric is entirely superior to Kevlar.”

The new invention is described as an “engineered carbon nanotube/heterocyclic aramid composite,” according to Zhang, who aims to create a catchy name similar to Kevlar in the future.

This material outperforms Kevlar, achieving the same ballistic protection with significantly less fabric. Zhang explains that each layer is roughly 0.6 millimeters thick and can slow a bullet’s speed from 300 meters per second to 220 meters per second. “Based on energy absorption calculations, about three fabric layers can halt a bullet,” resulting in a total thickness of 1.8 mm. In contrast, Kevlar would need to be at least 4 mm thick for equivalent protection.

Julie Cairney and her team at the University of Sydney in Australia have called the combination of aramid fibers and aligned carbon nanotubes revolutionary.

“This strategy could lead to the development of other innovative composite materials,” Cairney states, also highlighting that this manufacturing approach is compatible with existing industrial methods, indicating promise for scalable production and practical implementation.

“For personal and military protection, these materials have the potential to create lighter and more effective body armor, enhancing safety while maintaining mobility,” she adds.