Nylon

Nylon refers to a family of synthetic polymers characterised by amide linkages that join repeating units into long-chain polyamides. These materials are typically derived from petrochemical feedstocks and engineered to produce fibres, films, and moulded components. Nylons exhibit a range of physical properties—including strength, elasticity, chemical resistance, and thermoplasticity—which have made them central to industries such as textiles, engineering plastics, packaging, and automotive manufacturing.
As thermoplastic polymers, nylons soften when heated and can be extruded or moulded into a wide variety of forms. Their properties can be modified through copolymerisation or the addition of plasticisers, stabilisers, and fillers. Although raw nylon may have a subtle brownish tinge, it can be readily dyed and finished to achieve different textures, including silk-like lustre or soft matte appearances.

Chemical composition and classification

Nylon polymers are composed of repeating amide groups (–CONH–) formed through the condensation of diamines and dicarboxylic acids or through the ring-opening polymerisation of lactams. The nomenclature reflects the number of carbon atoms in the monomeric units.
• Nylon X,Y materials arise from diamines with X carbon atoms and diacids with Y carbon atoms; a major example is nylon 6,6, formed from hexamethylenediamine and adipic acid.• Nylon Z refers to polymers derived from single monomers with Z carbon atoms, as seen in nylon 6, synthesised from caprolactam.
These polyamides exhibit high tensile strength, abrasion resistance, and resilience. Their capacity to form hydrogen bonds between polymer chains contributes to their toughness and thermal stability. Nylons also possess good barrier properties, making them suitable for films used in food packaging.

Industrial applications

From their earliest commercial uses, nylon polymers have been applied extensively across multiple sectors. Their fibre forms appear in apparel, hosiery, carpets, and industrial textiles such as tyre cord, ropes, and parachute fabric. Injection-moulded nylon is common in mechanical components including gears, bearings, electrical housings, automotive fittings, and fasteners. Thin nylon films serve in packaging applications, especially where durability and oxygen resistance are required.
Blending with additives or other polymers can modify characteristics such as flexibility, impact strength, flame resistance, and UV stability. These engineering enhancements have allowed nylon to compete with and often replace natural fibres and metals in performance-based applications.

Historical development at DuPont

The invention of nylon was closely tied to DuPont’s polymer research efforts during the late 1920s and 1930s. Building on earlier work with rayon, the company reorganised its chemistry division to support fundamental research with practical potential. Wallace Hume Carothers, a pioneering chemist recruited to direct the project, conducted theoretical and experimental work on polymerisation that helped establish modern polymer science.
By 1930 Carothers’ team had synthesised several new polymers, including neoprene, a synthetic rubber. Continued investigation led to the development of “polymer 66”, later known as nylon 6,6. The breakthrough occurred in February 1935, when researchers successfully produced a strong, elastic polyamide with the required molecular weight and structural integrity. Carothers’ colleague Julian Hill contributed key processing insights through cold-drawing techniques that significantly improved strength.
DuPont filed patents for the new polymer in 1938 and rapidly consolidated production capacity. Although Carothers died before nylon’s public debut, his work became foundational to both polymer theory and industrial materials development. In parallel, German chemist Paul Schlack synthesised nylon 6 via caprolactam polymerisation in 1938, establishing a second major type of nylon produced internationally.

Early production and wartime significance

The first nylon plant opened in Seaford, Delaware, in 1939 and later became a National Historic Chemical Landmark. The initial commercial products included toothbrush bristles in 1938, but nylon gained widespread attention through women’s stockings, introduced at the 1939 New York World’s Fair and sold nationwide from 1940. Their popularity was immediate, with millions of pairs sold during the first year.
During the Second World War nylon production shifted largely to military uses, including parachutes, parachute cord, and other durable textiles. This transition highlighted the strategic value of synthetic polymers and greatly expanded the market for nylon. The material’s dependence on high-pressure chemical processes also strengthened the role of specialised departments within DuPont, particularly the Ammonia Department, which manufactured crucial intermediates.

Marketing and consumer reception

DuPont’s marketing strategy significantly shaped nylon’s public image. The fibre was promoted enthusiastically before mass availability, generating considerable anticipation. Presented as a modern, scientific material that was “as strong as steel and as fine as a spider’s web”, nylon symbolised technological progress. Exhibitions at the 1939–1940 world fairs helped establish it as a futuristic innovation.
However, early marketing claims led to consumer misconceptions. Some buyers believed nylon stockings would be unbreakable or indefinitely durable, leading to disappointment when the material behaved like a conventional textile. Concerns about synthetic materials also fostered unease among certain consumers. Rumours circulated that nylon was made from substances such as cadaver-derived chemicals, prompting DuPont to emphasise that nylon originated from coal, air, and water.
The company adapted its messaging to focus less on scientific novelty and more on comfort, fashion, and practicality. This shift helped to domesticate nylon as an everyday material rather than an exotic laboratory creation.

Legacy and continuing relevance

Nylon’s invention marked a turning point in polymer science and industrial chemistry. It was the first fully synthetic fibre to achieve commercial success and set a template for research collaboration, chemical engineering, and large-scale materials production. The nylon project indirectly revitalised parts of DuPont during the Great Depression, demonstrating the economic potential of innovative materials.
Today nylon remains one of the most widely used synthetic polymers. Its versatility—ranging from textiles and mechanical components to films and speciality applications—continues to make it a cornerstone of modern materials science. Its development illustrates how scientific research, industrial collaboration, and strategic marketing can converge to shape technologies that transform daily life.