High performance polymer fibres were first developed in the late 1960s with commercial production commencing in the 1970s. They were developed largely as a consequence of theoretical studies, which demonstrated that parallel orientation of polymer molecules and exploitation of the strength of carbon-carbon bonds would allow high strength materials to be produced. Techniques such as ultra-drawing, liquid crystal spinning and gel spinning were developed to provide highly oriented high performance polymer fibres. The first polymers to be studied were the aramids and polyethylene, resulting in commercial materials under the trade names Kevlar, Nomex, Technora, Twaron, Spectra and Dyneema. Other polymers have subsequently been evaluated, including liquid crystal polyesters (Vectran), PBZO and PBZT.

High performance polymer fibres, and the textiles and yarns made from them are replacing conventional materials in many applications, due to their high strength and low weight. Early problems are being overcome and applications range from sporting goods to oil rig tethers. Many civil engineering applications include cable stays and pre-stressed concrete structures. Bulletproof and pierce-resistant clothing is widely used. When high performance polymer fibres are incorporated in polymer matrices to form composites, a further wide range of products become possible. Weight reduction is a key factor in applications as diverse as car body shells and replacement hip joints.

Dr Peter Lewis is a Senior Lecturer in Materials at the Open University. He has expanded his expertise as a chemist with experience in the fields of metallurgy and engineering. His consultancy work encompasses failure diagnosis and new product design, particularly concerned with thermoplastics and composites, and he has authored more than 50 publications.

In this Rapra Review Report Dr. Lewis reviews the theory, development and uses of high performance polymer fibres. He describes their manufacture, and compares the properties of different polymers. Applications of different materials are described, together with their advantages and limitations. His review is complemented by the addition of a fully indexed set of references and abstracts selected from the Polymer Library. These provide further reading on the technology and uses of high performance polymers.

High performance polymer fibres are relatively new materials with a lot of potential for the future. Their remarkable properties frequently outweigh their high production costs, as they replace traditional materials and find entirely new applications. This Rapra Review Report demonstrates the current state of the art in a fascinating and fast-moving field.