Ballistic nylon, a material known for its exceptional toughness, was developed by DuPont during World War II. It was originally used to create flak jackets to protect airmen from shrapnel and fragmentation, earning its “ballistic” name. Today, consumers frequently encounter this fabric in high-end luggage, tactical gear, and heavy-duty backpacks. Understanding the material’s construction and applied treatments is necessary to determine if it is water resistant or truly waterproof.
Understanding Ballistic Nylon’s Structure
Ballistic nylon’s natural resistance to moisture stems from its specific construction, separate from any chemical treatments. This fabric is woven from high-tenacity nylon yarn, typically with a denier count of 840D, 1050D, or 1680D, where the higher number indicates a thicker, more robust yarn. The original specification was 1050 denier nylon woven in a tight 2×2 basketweave pattern.
This characteristic basket weave creates a dense textile with minimal gaps between the fibers. The tightly bound structure mechanically impedes the easy passage of water molecules, causing water to bead up and run off the surface rather than immediately soaking in. The inherent properties of nylon fiber itself also contribute, as its molecular structure inhibits water penetration to some degree, making the material naturally water repellent and resistant.
Water Resistance Versus Waterproofing
The distinction between water resistance and waterproofing directly answers the question of ballistic nylon’s capability. Water resistance means a fabric can effectively repel light splashes and momentary contact with water, slowing down penetration. Untreated ballistic nylon falls into this category; its tight weave can handle light rain or a quick spill, but it will eventually absorb moisture under sustained exposure or pressure.
Waterproofing, in contrast, requires a material to completely prevent water penetration even when subjected to significant and prolonged pressure. This capability is measured by the hydrostatic head test, which determines the height of a water column, measured in millimeters, that a fabric can withstand before a leak occurs. A fabric is considered waterproof only when it can withstand a water column of at least 10,000 mm. Since the structure of ballistic nylon alone does not create an impermeable barrier, it cannot meet these high hydrostatic head standards without further modification.
Enhancing Protection: Coatings and Liners
To achieve waterproofing, manufacturers apply barrier layers to the woven ballistic nylon fabric. The most common method involves applying a coating to the interior side of the material, which creates a continuous, non-porous film that the nylon weave inherently lacks. Polyurethane (PU) coatings are frequently used for this purpose, offering a balance of durability and flexibility while significantly enhancing water resistance and achieving higher hydrostatic head ratings.
For applications requiring extreme performance, such as heavy-duty tarpaulins, Polyvinyl Chloride (PVC) coatings may be used, which can deliver waterproof ratings exceeding 20,000 mm. Additionally, the fabric’s exterior face is often treated with a Durable Water Repellent (DWR) finish. This chemical treatment causes water to bead and roll off the surface immediately, preventing the face fabric from becoming saturated and maximizing the effectiveness of the interior coating.
The Primary Strength of Ballistic Nylon
While its water performance is a common consideration, the primary focus of ballistic nylon is extreme durability and resistance to physical damage. The material’s high denier count and robust basket weave were originally designed to resist fragmentation and shrapnel, not water. This construction gives it exceptional tensile strength and superior resistance to punctures, tearing, and abrasion.
The ability to withstand constant rubbing against rough surfaces is why ballistic nylon is widely used for heavy-wear consumer goods. Applications like high-end travel luggage, motorcycle gear, heavy-duty tool bags, and tactical equipment prioritize this resilience over a need for complete, submersible waterproofing. Its strength ensures a long product lifecycle in demanding environments where the risk of the material tearing or wearing thin is the more significant concern.