Nylon vs Polyester Webbing: Pros & Cons
Nylon & Polyester: Composition Matters
Nylon webbing is a synthetic, high-tenacity fiber known for excellent strength, abrasion resistance, and elasticity under load bearing situations. Its tensile strength can reach up to thousands of pounds per inch in configurations, which makes it ideal for high-stress applications like use in backpacks, parachutes, and belts. Polyester webbing is also a synthetic fiber, engineered to deliver stable tensile strength, UV resistance, and with minimal stretch in load bearing situations. Its strength rivals nylon but it has far lower elongation characteristics, which makes this ideal for applications like use in truck tie downs, cargo strapping, and applications requiring pulling, lifting or dragging like tow straps.
- Nylon: Resilient with generally a 18–25% elongation at break; higher initial tensile strength than polyester.
- Polyester: Lower elongation at a typical 6–18% elongation at break; maintains shape under repeated load; less deformation from moisture than nylon and has higher UV resistance.
Key Head-to Head Performance Comparisons
Abrasion & Cut Resistance
- Nylon: Excels against abrasion; perfect for high-wear environments.
- Polyester: Is also highly abrasion-resistant, with added benefit of retaining structure under prolonged use.
UV & Weather Resistance
- Nylon: Moderate ability, prone to accelerated degradation with prolonged sunlight and UV exposure.
- Polyester: Outstanding as it maintains integrity, color, and tensile strength after UV exposure; better choice for outdoor use.
Moisture Absorption & Chemical Resistance
- Nylon: Hydroscopic, so it absorbs moisture, increasing weight and reducing strength in wet conditions; less effective with many acids and bleaches.
- Polyester: Hydrophobic, it barely absorbs water, resists mold/mildew; impervious to most acids and common chemicals.
Temperature Tolerance & Flame Resistance
- Nylon: Performs in a wide temperature range but will deform when exposed to high heat. Can be treated with a topical treatment for flame retardant standards for safety.
- Polyester: Superior heat and flame resistance, surpassing many critical standards for critical safety.
Cost, Availability, and Lifecycle
- Cost & Availability: Polyester yarn is generally lower priced and has a more stable global supply relative to nylon. The kicker, of course, is that domestic berry compliant polyester has an extremely small supply chain and oftentimes is unable to be sourced berry compliant. Nylon on the other hand can be produced and sourced within the US to meet berry compliance.
- Lifecycle: Polyester maintains performance longer under exposure to sunlight, moisture, and chemical agents, which offers longer term cost savings in challenging environments.
Application |
Nylon Webbing |
Polyester Webbing |
Military & Tactical |
Belts, packs, load carriage |
Harnesses, load-bearing straps —max UV/water resistance desired |
Industrial & Safety |
Helmet lining, gloves, chin straps, knee/elbow pads |
Cargo tie-downs, strapping, fall protection—minimal stretch improves security |
Aerospace & Automotive |
Straps, reinforcement, critical supports, handle straps |
Seatbelts, harnesses, aircraft cargo netting, parachutes |
Marine & Outdoor |
tents, high-wear handles |
Mooring, rigging, outdoor tie-downs—max durability & outdoor reliability, awnings |
Commercial & Apparel |
Backpacks, luggage, tactical accessories, pet leashes |
Sports straps, PPE, apparel belts |
In-Depth: Pros & Cons of Each Material
Nylon Webbing Pros
- Superior tensile strength per unit weight
- High abrasion and shock absorption, useful for dynamic loads
- Good performance in indoor and moderate outdoor use
- Berry compliant options readily available
Nylon Webbing Cons
- Loses tensile strength and absorbs water in wet conditions
- Less effective UV resistance, can degrade outdoors over time
- Susceptible to acids and chlorine bleach
Polyester Webbing Pros
- Maintains shape, minimal stretch, even when wet or under continuous load
- Higher UV and moisture resistance, holds up in hot, sunny, humid, marine, or chemical-exposed environments
- More cost-effective and long-lasting in challenging conditions
Polyester Webbing Cons
- Slightly less elastic, so not ideal for certain shock-absorbing applications
- Marginally lower abrasion resistance compared to nylon used in some configurations
- The majority of the supply chain is located in China. Berry compliant options are not readily available.
Cost, Compliance, & Sourcing with ACW
ACW is a recognized leader in global webbing production with production capacity in the USA and overseas in multiple countries. We can make every yard of our nylon and polyester webbing products at our Rhode Island plant. You can rely on ACW’s quality control to meet military, industrial, and commercial requirements and boast a 95.3% on time delivery to customers. From custom dye lots for tactical gear, to rugged flame-resistant harness webbing, ACW operates an ISO-certified facility to meet the highest quality standards. We have extensive expertise with companies struggling to move products out of R&D through rapid prototyping and into scalable production.
- Berry Compliant: ACW manufactures webbing in strict adherence to government and defense sourcing standards. We completely support mission readiness for military projects.
- Made in the USA: ACW also makes webbing in the usa using import yarns. All the webbing is woven and dyed in Rhode Island.
- Commercial made Overseas: ACW makes webbing in a number of different countries overseas, offering webbing for load bearing to low end commercial products FOB Rhode Island.
- Technical Partnership: ACW’s engineers and weaving specialists will assist with material selection, prototyping, design.
Make the Right Choice for Your Application
Both nylon and polyester webbing offer robust performance. The optimal selection hinges on the specific demands for your project and end uses, such as load profiles, environments, chemical exposure, and cost constraints. Engineers and buyers are invited to consult with ACW’s technical staff for tailored material and construction recommendations.