Kevlar Lamellar & Shields - Now Taking Orders

[Atlanta Armory]

I am now taking orders for lamellar and shield blanks made from lightweight kevlar composite.


Shields:

Currently my molds are limited in size to roughly 16" x 23" and flat in profile. This allows for smaller round shields, and Roman scutums are in the works (I have to find someone who has and is willing to let me use their autoclave). Shields without a core are going to be roughly 1/8" in thickness. Basswood core, which stiffens the shield and adds about 1/8" in thickness, will be available as an option.

Simple 16" x 23" blank - $50, 2.5lb
+ core - $50, 1.0lb.

The actual weight may vary depending on how many layers I have to end up using. The cored shield blanks with have a 1/16" skin on each side of the core. They will come smooth on the front and back surfaces and rough around the edges. Allow 1/4" - 1/2" on each side for trimming. The kevlar will be visable and will need painting to help protect it from UV light. A canvas covering is recommended but not required.

Lamellar:

This will come in 16" x 23" x 1/16" (can do custom thicknesses) sheets. The individual plates will need to be cut out with a shear or band saw but the lacing holes (they are not drilled, but rather the fabric is forced around pins that are the diameter of the holes and reenforced) and a cut pattern will be provided. Each cured sheet will be $35, which comes out to around $0.60 and 0.3 oz per plate assuming 3.75" x 1.5" plates.

I don't have the molds completed yet for the lamellar so there's still time to change the hole pattern if needed. Right now I am leaning towards the style shown here: http://www.armourarchive.org/patterns/l ... emplarbob/ I may also use this pattern here if there is enough interest (thanks Tatsuo Okami for the pattern): http://www.armourarchive.org/patterns/o ... lampat.jpg & http://www.armourarchive.org/patterns/o ... acing1.jpg. If you have a preference other than what's shown, please post a link or pic of an example (and the designer's contact info if it's not an original). I also need to know what size holes you'd prefer. Tatuo Okami's pattern uses 1/8" holes for lacing, but I've seen all the way up to 7/32" (roughly 5-6mm).

-Ben

[Payn]

what are the durability expectations?

[Atlanta Armory]

Should be about as rigid as aluminum in the same thickness and several times stronger. The cored material will be substantially stiffer, though the strength will most likely be limited by the core, not the kevlar.

I don't know how if will fatigue, but if it doesn't hold up I'll add more layers and send free replacements.

-Ben