Development of Kevlar/Sawdust Reinforced Polypropylene Blend Hybrid Composite for High Impact Application

Résumé

This thesis focuses on the development of a Kevlar/sawdust reinforced polypropylene hybrid composite designed for high-impact applications. The study explores the integration of Kevlar fibres, known for their exceptional strength and toughness, with sawdust, a low-cost and sustainable by-product, within a polypropylene matrix. Using a hand lay-up technique, composite samples were produced with varying sawdust compositions and ten layers of Kevlar reinforcement. Mechanical evaluations were conducted to determine water absorption, hardness, and impact resistance. Results revealed low water absorption (0.56–0.79%), indicating excellent moisture resistance. Hardness values increased consistently from 83.5 to 93 Shore D, while impact strength improved from 19.0 J/mm to 23.5 J/mm as reinforcement content increased. These findings demonstrate that the hybrid composite offers superior mechanical performance, cost efficiency, and environmental benefits. The material shows strong potential for use in automotive, aerospace, construction, and protective equipment industries requiring lightweight and durable high-impact resistant solutions.

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