In this work, several weaving designs of intra-ply woven fabric Kevlar/hemp fiber (KHE) reinforced epoxy hybrid composites are developed and their thermal characteristics are examined. Thermogravimetric analysis showed that intra-ply hybrid of plain and basket weave designs possessed highest thermal stability. The different weaving patterns of KHE hybrid composites have no effect on the glass transmission temperature (Tg) value as inferred from the differential scanning calorimetry results. The thermomechanical analysis clearly demonstrates the superior dimension stability of the hybrid composites with basket weave. Dynamic mechanical analysis reveals that twill weave KHE have exhibited the maximum storage modulus (2021 MPa), loss modulus (210 MPa) and lower tan delta (0.3090) values compared to all other composites. Based on the obtained results, it is denoted that all the fabricated KHE hybrid composites displayed improved thermal performance. It may be suitable for applications in thermal insulation panels, fire-resistant clothing, and automotive underbody shields.