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Laminated composites are subject to delamination. This study aims to address this drawback and obtain structurally stable, lightweight, thin laminated composites through a novel manufacturing method that involves blending thermoplastic polyurethane (TPU), low‐melting polyester (LMPET), and Kevlar. Nonwoven LMPET/Kevlar fabrics are first processed through a nonwoven technique and then combined twice with TPU sheets through the sheet extrusion method. The mechanical properties, thermal behavior, and combustion resistance of the laminated TPU/LMPET/Kevlar composites are then evaluated. Results show that LMPET fibers strengthen adhesion between TPU and nonwoven laminates, and the addition of a small amount of TPU increases the peeling strength of the laminated TPU/LMPET/Kevlar composites by 1.9‐fold. The distribution of Kevlar fibers enhances the tensile properties and flame resistance of the laminated composites. Specifically, the tensile strength of the laminated TPU/LMPET/Kevlar composites reaches 18.85 MPa, and their combustion rate is significantly reduced. The proposed manufacturing design efficiently reduces delamination, thus extending the application range of laminated TPU/LMPET/Kevlar composites. POLYM. COMPOS., 40:E550–E558, 2019. © 2018 Society of Plastics Engineers [ABSTRACT FROM AUTHOR]