Laser cutting technical fabrics - minimal waste, prevents fraying, intricate designs

Military style backpack made from laser cut Cordura fabric

Laser cutting technical fabrics - minimal waste, prevents fraying, intricate designs

Technical fabrics are developed for their performance rather than their appearance. These fabrics are designed to offer functionality, such as durability, breathability, absorption, waterproofing, auditory protection, fire resistance, or antimicrobial properties.

They are commonly used in sportswear, protective clothing, medical textiles, automotive and marine interiors, and industrial applications.

The key benefits of laser cutting technical fabrics includes low tolerance cutting with minimal fabric waste, sealed edges to prevent fraying, the ability to cut intricate designs, fast processing speeds and the flexibility to work with various technical fabric types.

Laser cut Gaskets Laser Cutting Sportswear Laser Cutting for Military Protective Gear

Laser cut Gaskets

Gaskets are used across industries like automotive, aerospace, oil & gas, and pharmaceuticals. They’re essential for sealing joints, preventing leaks, and handling extreme temperatures, pressures, and chemicals. Laser cutting provides tight tolerances, and the ability to create complex shapes, making it an ideal method for both custom prototypes and large-scale gasket production.

Triangle laser cut in blue women's sports top

Laser Cutting Sportswear

Lycra and other stretch fabrics are widely used in sportswear due to their flexibility, comfort, and durability. Laser cutting offers a clean, consistent way to cut these materials without causing fraying or distortion.

This method is ideal for cutting both full garment panels and decorative features within those panels, giving designers greater freedom for creativity while keeping the structure of the fabric intact. It’s also efficient — helping reduce fabric waste and speed up production without compromising quality.

Laser cut cordura fabric for military clothing and protective gear

Laser Cutting for Military Protective Gear

Laser cutting offers a reliable, efficient way to shape tough, high-performance materials used in military and tactical applications. It’s especially effective for textiles like Kevlar and Cordura, which are known for their strength and durability.

Kevlar, commonly used in body armour and ballistic protection, benefits from sealed edges that reduce fraying and preserve integrity. Cordura, valued for its abrasion resistance, is ideal for MOLLE systems, tactical pouches, and load-bearing gear.

At Laser Cutting Services, we work with defence suppliers and tactical gear manufacturers to deliver high-quality cutting, short lead times, and expert support for demanding projects.

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Engineering/Industrial parts and components

Laser cutting is the preferred method for cutting high-performance geotechnical textiles and civil engineering materials. These are commonly used in infrastructure projects such as roads, railways, coastal protection, aerospace, landfills, and erosion control.

Engineers incorporate geotextiles into various designs, requiring precision to maintain performance. Laser cutting ensures clean, sealed edges, preventing fraying through heat application.

Examples of these textiles include Kevlar (Aramid), Nomex (Meta-Aramid), Vectran (LCP), Zylon (PBO), carbon fibre, UHMWPE, and specialised polyester fibres such as Coolmax. These materials are often engineered for properties such as fire resistance, high tensile strength, moisture-wicking, and extreme durability.

Oil, gas and water industries

Laser cutting can be used to cut engineering components enabling effective repairs to damaged pipes, such as cracks, breaks, or blockages. Custom cut to fit a variety of pipe sizes and materials.

Positioning and navigation

Single and multilayered gaskets are laser cut to fit in GPS and navigation systems for use across marine, aircraft, and in the military.

These seals protect sensitive electronics by ensuring watertight, dustproof, and vibration-resistant enclosures.

Fashion, Sportswear and Protective Clothing

In industries such as fashion, sportswear, and protective clothing for military and police, technical fabrics are chosen for their specific properties, such as durability, flexibility, breathability, or resistance to fire and abrasion.

A key application of laser cutting in these industries is the production of pattern pieces for garment construction.

This method of fabric cutting is widely adopted due to its efficiency, repeatability, and ability to handle complex designs with minimal waste.

Fashion Industry

Laser cutting enables designers to create intricate patterns, seamless finishes, and unique textures that are difficult to achieve with traditional cutting methods. Common technical fabrics used in fashion include:

Neoprene – Used for structured garments and contemporary fashion pieces.
Lace & Mesh – Ideal for delicate detailing without the risk of fabric distortion.
Leather & Faux Leather – Used for accessories, trims, and statement pieces.

Sportswear & Performance Apparel

Brands like Nike, Patagonia and The North Face use technical fabrics for sportwear and performance apparel. Laser cutting ensures sealed edges, prevents fraying. Key materials include:

Compression Fabrics (Lycra, Spandex) – Used for high-performance leggings, cycling gear, compression socks which all aid circulation support and injury recovery.
Breathable Mesh & Moisture-Wicking Fabrics – Essential for sports tops and activewear
Softshell & Windproof Materials – Used in outdoor and winter sports gear.
Reflective & High-Visibility Textiles – Ideal for running and cycling apparel for increased safety.

Protective Clothing for Military & Police

Laser cutting preserves the structural integrity and protective properties of military and police clothing. Materials include;

Kevlar & Aramid Fabrics – Used in bulletproof vests, tactical gloves, and reinforced clothing.
Nomex & Fire-Resistant Textiles – Essential for flame-resistant military and police uniforms.
Cordura & Ballistic Nylon – Used in durable combat uniforms, backpacks, and gear pouches.
Camouflage & Infrared-Reflective Fabrics – Designed for stealth and protection in military operations.

Medical market

PPE Applications – Laser cutting ensures the precise, clean cuts needed for medical-grade personal protective equipment (PPE), such as face & eye shields, improving both safety and comfort.

Luxury Fit-Outs & Upholstery in Yachts, Cars & Interiors

Laser cutting is widely used in the luxury interior and upholstery industry, offering efficiency and accuracy when working with high-end materials. This method allows for intricate detailing, custom patterns, and seamless finishing in projects such as yacht interiors, automotive upholstery, and bespoke furniture.

Common Fabrics & Their Applications

Alcantara & Suede – Used for luxury car dashboards, seat upholstery, and yacht interiors due to its soft texture and durability.
Leather & Vegan Leather – Ideal for custom car interiors, steering wheel covers, and seating in private jets, yachts, and high-end furniture. Frequently used due to their premium feel and longevity.
Wool & Cashmere Blends – Commonly used for premium automotive interiors, luxury seating, and wall panels in yachts and private residences.
Velvet & Chenille – Adds a plush, sophisticated finish to luxury seating, headliners, and soft furnishings.
Technical Upholstery Fabrics (Nomex, Fire-Retardant Textiles) – Required for aviation, marine, and high-end hospitality fit-outs to meet safety regulations.
Acoustic Fabrics such as Velour Fabric, Recycled Polyester, B fabric and Acoustic Felt – Acoustic fabrics are designed to absorb sound and reduce noise levels. They are often used for wall coverings, ceiling tiles, curtains, or acoustic panels, offering both aesthetic appeal and noise reduction benefits.

Laser cutting enables intricate patterns, perforations, and seamless customisation, making it the preferred choice for luxury design projects.

What are the benefits of laser cutting technical fabrics?

✔ Accurate Cutting with Tight Tolerances

✔ Consistency in Every Cut

✔ Efficient for High-Volume Production

✔ Optimized Material Use with Nesting √Self-Sealing Edges

✔ Minimal Burn Marks √Capable of Handling Large Roll

✔ Compatible with Most Materials

✔ No Colour or Thickness Restrictions

Other companies declined as too big a job. There's no way we could have done it without your tireless efforts; we're so appreciative of your proactive attitude and incredible hard work you put in to make our Christmas campaign a success.

Stef Midmer - Senior PR, Virgin Trains

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