What Thread Should You Use to Sew Nylon Webbing?

In the manufacturing of nylon webbing products, stitching is not a secondary detail—it is a structural component. For load-bearing, tactical, or industrial applications, the strength of the seam is often more critical than the webbing itself. If the thread is improperly selected, even the highest-quality nylon webbing will fail under stress.

Stitching as a Load-Bearing Element

Nylon webbing is designed to withstand tension, abrasion, and repeated use. However, the seam is typically the first point of failure when products are overloaded or improperly constructed. For this reason, the sewing thread must be carefully matched to the webbing’s material, thickness, and intended application.

In commercial production, thread selection directly affects:

• Seam tensile strength

• Product service life

• Performance under dynamic load

• Compliance with customer and industry standards

Recommended Thread Types for Nylon Webbing

Bonded Nylon Thread – Standard for Tactical and Industrial Use

Bonded nylon thread is the most commonly used thread for sewing nylon webbing in professional manufacturing environments.

Its high tensile strength and abrasion resistance make it suitable for demanding applications. The bonding process reduces friction during sewing, minimizes fraying, and ensures consistent stitch formation at high production speeds.

Bonded nylon thread is widely used in:

• Tactical backpacks and load systems

• Military belts and straps

• MOLLE platforms

• Industrial safety products

For most B2B nylon webbing products, bonded nylon thread provides the best balance of strength, durability, and cost efficiency.

Bonded Polyester Thread – Preferred for Outdoor Exposure

For products intended for long-term outdoor use, bonded polyester thread is often recommended. Compared to nylon, polyester offers superior resistance to UV radiation and environmental aging.

This makes it suitable for applications such as:

• Outdoor equipment

• Marine and coastal products

• Exposed straps and tie-downs

While polyester thread has slightly lower elasticity than nylon, its long-term stability in outdoor conditions is a key advantage for certain markets.

Aramid (Kevlar®) Thread – Specialized Applications Only

Aramid threads, such as Kevlar®, are used in extreme conditions requiring high heat resistance, flame retardancy, or exceptional tensile strength.

Due to their high cost and sewing complexity, these threads are typically limited to specialized military, aerospace, or fire-resistant products. They are not recommended for standard nylon webbing applications unless specifically required by the end use.

Thread Size Selection in Production

Thread size must be selected based on webbing width, thickness, and load requirements. Undersized thread may sew cleanly but will not meet strength expectations in service.

Typical guidelines in B2B production include:

• Tex 70 for light-duty applications

• Tex 90 for medium-duty webbing

• Tex 135 or higher for heavy-duty or load-bearing products

For military or safety-critical products, heavier thread sizes are generally specified to ensure adequate safety margins.

Stitch Quality and Process Control

Thread performance is closely linked to sewing process control. Proper needle selection, stitch pattern, and tension adjustment are essential for maintaining seam strength and consistency.

Common industrial practices include:

• Heavy-duty needles designed for synthetic materials

• Reinforced stitch patterns such as box-X or multi-row lockstitch

• Routine testing of seam strength during production

A controlled sewing process ensures that the stitching performs at the same level as the webbing itself.

Conclusion

In B2B nylon webbing manufacturing, thread selection is a critical engineering decision. Bonded nylon thread remains the standard choice for most tactical and industrial applications, while bonded polyester thread is preferred for products exposed to prolonged outdoor conditions. Specialized threads should be used only when required by the application.

By selecting the correct thread and maintaining consistent sewing standards, manufacturers can ensure reliable seam performance and long-term product durability for professional customers.