Kevlar 49 vs PBO (Zylon)
Composite · grade comparison
Kevlar 49 and PBO (Zylon) are both composite grades. PBO (Zylon) is the stronger of the two: tensile strength 5,800 MPa (841 ksi) against 3,000 MPa (435 ksi) for Kevlar 49, about 93% more. PBO (Zylon) is the more ductile: elongation 3.5% versus 2.4% for Kevlar 49. Kevlar 49 is lighter (1.44 g/cm³ vs 1.54 g/cm³ for PBO (Zylon)) and PBO (Zylon) is stiffer (180 GPa vs 112 GPa). On the shop floor, Kevlar 49 machines more easily (25 vs 15 out of 100).
Kevlar 49Choose it when weight is the constraint, or when the part is machined in volume.
PBO (Zylon)Choose it when strength drives the design, or when the part is bent, formed or impact-loaded.
Kevlar 49 vs PBO (Zylon): propertiesHow to read these bars
- One bar per material. A full bar is the highest value among all composite grades in the FabDigit library; each bar is drawn as a share of that.
- The better value (by the usual engineering direction) is in bold. Rows with no direction — density, thermal conductivity — have no bold.
- Values are typical room-temperature figures for the condition named on each card.
- Confirm against the certified mill or resin datasheet before design release.
How to read these bars
- One bar per material. A full bar is the highest value among all composite grades in the FabDigit library; each bar is drawn as a share of that.
- The better value (by the usual engineering direction) is in bold. Rows with no direction — density, thermal conductivity — have no bold.
- Values are typical room-temperature figures for the condition named on each card.
- Confirm against the certified mill or resin datasheet before design release.
Mechanical
Strength, stiffness, ductility and hardness at room temperature.
Elastic (Young's) Modulus
Shear Modulus
Poisson's Ratio
Tensile Strength (Ultimate)
Elongation at Break
Compressive Strength
Physical
Density and transition temperatures.
Density
Glass Transition (Tg)
Water Absorption (Saturation)
Water Absorption (24 h)
Thermal
How each material carries heat and how hot it can run.
Thermal Conductivity
Specific Heat Capacity
Thermal Expansion (CTE, 20–100 °C)
Max Service Temperature (continuous)
Limiting Oxygen Index
Max Service Temperature (short-term)
Same in both: Min Service Temperature -196°C-321 °F
Electrical
Conductivity and insulation.
Electrical Resistivity
Dielectric Constant (1 MHz)
Dissipation Factor (1 MHz)
Volume Resistivity
Chemical & Environmental
Corrosion and environmental resistance (0–100 scores).
UV / Weathering Resistance
Same in both: Corrosion Resistance 70 / 100
Manufacturability
FabDigit workshop ratings (0–100 scores) — how each material behaves on the machine.
Machinability
Sustainability
Primary-production footprint per kilogram.
Embodied Energy (primary production)
Embodied Carbon (primary production)
Same in both: Typical Recycled Content 0%
Common Calculations
Ratios derived from the values above.
Specific Strength (UTS / density)
Specific Stiffness (E / density)
Strength versus weight
Yield strength against density for every composite grade in the FabDigit library; the compared grades are highlighted. Up and left is stronger for its weight.
Manufacturing and finishing
| Capability | Kevlar 49 | PBO (Zylon) |
|---|---|---|
| Default condition | — | — |
| Relative cost | $$$$ High | $$$$ High |
| Min. machined wall | — | — |
| Best machined surface | — | — |
Kevlar 49 vs PBO (Zylon) — frequently asked
Is PBO (Zylon) stronger than Kevlar 49?
Yes. PBO (Zylon) has a typical tensile strength of 5,800 MPa (841 ksi) against 3,000 MPa (435 ksi) for Kevlar 49 — about 93% more.
Which is cheaper, Kevlar 49 or PBO (Zylon)?
Both sit in the same relative cost tier ($$$$, high); the part price will be decided by machining time, tolerance and quantity rather than by the material.
Which is easier to machine, Kevlar 49 or PBO (Zylon)?
Kevlar 49, by a small margin. Both rate poor for machinability — 25/100 against 15/100 for PBO (Zylon).
Ready to make it?
Upload a CAD file and FabDigit prices the part in Kevlar 49 and PBO (Zylon) side by side — material, machining time, tolerance and finish in one quote. Certified material data ships with the order on request.
Typical handbook values for the conditions named above, normalised for comparison. Hardness on non-Brinell scales is converted approximately for charting only. Request certified data with your order for design-critical properties.