Ballistic Nylon

Overview

Ballistic fabrics are tough, durable materials originally designed for military use, specifically to protect against shrapnel and fragments. Their dense weave and high-strength fibers make them incredibly resistant to tearing, abrasion, and wear. Some common applications of ballistic fabrics are luggage, motorcycle gear, protective gear, and pet accessories. Known for their durability and reliability, ballistic fabrics undergo strict testing to ensure they can handle the stresses of real-world use.

The History of Ballistic Fabrics

Ballistic nylon was originally created by DuPont during World War II as a protective fabric to be used in military flak jackets. Although it was intended to shield soldiers from exploding fragments and shrapnel, today’s ballistic nylon has many applications, for the general population as well as in the military and industrial world. It’s strong, durable, and can withstand extreme conditions. Ballistic nylon is not truly bulletproof, but it does offer a tremendous resistance to cuts, tears, and punctures, making it popular for motorcycle gear, among other things.

Construction and Composition of Ballistic Fabrics

Ballistic fabric is typically constructed from nylon 6,6 or nylon 6, but it’s distinguished by its “ballistic weave”, a tight, basket-weave pattern. Common weaves include 2×2 or 3×3, meaning multiple threads are woven together in each direction to create a denser, stronger fabric.

The denier (weight and thickness of the fiber) of ballistic fabric ranges widely. Standard ballistic fabric is generally 840D or higher, with 1050D and even 1680D being common for heavy-duty applications. Ballistic fabric was one of the first fabrics to be produced in very high denier ratings (usually 840D or higher). This high denier is part of what gives it its famously tough, thick feel.

For added durability and performance, ballistic fabric is often treated with coatings such as polyurethane or PVC. These finishes enhance water resistance, UV resistance, and abrasion protection.

Properties of Ballistic Fabrics:

• Abrasion Resistance: Due to its dense weave and high denier, ballistic fabric withstands repeated abrasion better than most other fabrics. Due to its high abrasion resistance, ballistic fabric is a popular choice for motorcycle jackets and pants, making it a go-to material for protective, roadready gear. Its smooth surface even helps reduce friction in the event of a slide
• Tensile Strength: Ballistic fabric has high tensile strength, making it resistant to tearing and puncturing.
• Weather Resistance: With the right coating, ballistic fabric can resist moisture and UV exposure, making it ideal for outdoor and rugged environments. NASA has used ballistic fabric in various applications, including in the construction of spacesuits and other gear. Its resistance to extreme conditions makes it ideal for space-related uses.

Top 5 Applications of Ballistic Fabrics

1.     Military and Tactical Gear: Ballistic fabric is widely used in military applications, including in vests, backpacks, and harnesses, where durability and strength are critical.

2.     Protective and Industrial Equipment: From tool bags to industrial gloves and aprons, ballistic fabric is valued in industries requiring protection from sharp tools and abrasive environments.

3.     Luggage and Travel Accessories: Many high-end travel bags, suitcases, and laptop bags are made from ballistic fabric due to its durability, which can withstand rough handling and frequent travel.

4.     Motorcycle Gear: Ballistic fabric is used in jackets, pants, and accessories designed to protect riders from road rash and impact during accidents.

5.     Pet Accessories: High-durability pet collars, leashes, and harnesses are often made from ballistic fabric to withstand wear and tear from pets’ active lifestyles.

Ballistic Nylon vs Cordura Nylon

• Structure: While ballistic nylon has a smooth, dense weave, Cordura nylon typically has a textured, rough weave. Cordura is often preferred for outdoor gear due to its rugged, natural feel.
• Applications: Ballistic nylon is favored for applications requiring high tensile strength and abrasion resistance, while Cordura is commonly used for backpacks, outdoor apparel, and military gear.
• Strength and Durability: Both are highly durable, but ballistic nylon’s tighter weave gives it an edge in tear resistance, while Cordura is prized for its high resistance to wear. Ballistic nylon is put through a variety of 3rd party testing to confirm it meets the rigorous standards for strength and durability required across various industries. Here are some of the key testing methods used to make sure ballistic nylon is up to snuff:

Top 4 Testing Methods of Ballistic Fabrics

1. Abrasion Testing (ASTM D3884): Abrasion resistance is tested using a rotary platform or other abrasion machine to determine how much wear the fabric can withstand before fibers break down. This is crucial for applications in luggage and protective gear.

2. Tensile Strength Testing (ASTM D5034): Tensile strength tests determine the fabric’s resistance to pulling forces. High denier ballistic fabrics generally score high on tensile strength tests, making them suitable for industrial and protective applications.

3. Tear Strength Testing (ASTM D2261): The fabric is tested for resistance to tearing, essential for materials intended to endure harsh environments, such as motorcycle gear and industrial bags.

4. Water Repellency Testing (AATCC 22): Water repellency tests are conducted on coated ballistic nylon fabrics to measure how well they resist water penetration, which is important for outdoor and military applications.