A process for the molding of Kevlar composite parts that are strong, lightweight, and flexible. A thermosetting or thermoplastic resin powder is used to impregnate the Kevlar fibers using a proprietary process that involves temperature- and pressure-controlled compression to form the complex composite parts. The parts formed using this method are lightweight and have low thickness with high strength and good toughness. Usually the composition of the composite is in the range of 45%~65% Kevlar, 45%~30% epoxy, and 10%~5% polycarbonate (PC). Kevlar has high strength and good toughness, and the fiber orientation can be customized to ensure both of the parts meet various performances and reliability tests. For a thermoset resin impregnation, the Kevlar is first soaked in resin, then cut, formed to shape, and finally painted. For a thermoplastic-resin-impregnated composite part, after cutting of the composite matrix, rapid warming and cooling is required. It is available in 9 different colors of fibers, including natural, black, gray, red, orange, silver, blue, green, and brown, and in twill or plain weave pattern. Customization of size, thickness, color, patter, and finish is possible. Applications include smart phone covers and cases, interior parts for automotive, marine and aviation industry, parts for drones, AR/VR/MR headsets, and home appliances.