How Is Nylon Made?
Wallace Carothers at DuPont created the first nylon material on 28 February 1935; it remains one of the most widely used synthetic fabrics. The term itself is actually used to refer to a broad range of polyamides, or synthetic polymers. Creating useful nylon is a two-step process; first, chemicals are combined to create the material itself, and second, the material is manufactured to make it useful.
The Chemical Process of Creating Nylon
To create nylon, the manufacturer combines two sets of molecules. One set has an acid group on each end, and the other set has an amine group, made up of basic organic compounds, on each end. The result of this combination is a substance that is known as nylon 6, 6 or nylon 6-6. The name is based on the number of carbon atoms between the two acid groups and the two amine groups.
Nylon can be chemically created in a different way as well — the same molecules are used, only they're molded into a different structure. In this alternate method, the acidic molecules are all at one end of the structure, and the amine molecules are all at the other. This compound is then combined into a chain of carbon atoms.
The high-temperature chemical reaction required to create nylon is conducted in a specially designed machine. To create the chemical compound, the chemicals combine to form molten nylon. This semi-liquid material is then forced into a spinneret, which is used to separate the nylon into thin strands.
The Manufacturing Process of Creating Useful Nylon
When the nylon moves through the spinneret, it is exposed to the air for the first time. The air causes the strands to harden immediately and once they are hard, they can be wound onto bobbins. The fibers are stretched to create strength and elasticity — a key benefit of nylon. The filaments are unwound and then rewound onto another, smaller spool. This process is called drawing and is used to align the molecules into a parallel structure.
After the nylon has been wound onto the smaller spool, it is ready for use. Nylon products are created by weaving the filaments together. The tighter the weave, the more strength the fabric will have.
Nylon can also be mixed with other fibers to create combination materials. A combination of cotton and nylon produces a resilient material that holds its shape but is soft to the touch. Nylon can also be woven into patterns to reinforce strength, improve appearance or meet other design requirements.
Written by Carol Francois
