Nylon injection molding is a manufacturing process that uses molten nylon — a type of engineering thermoplastic — to produce durable, lightweight, and high-strength components. Nylon, also known as polyamide (PA), is a semi-crystalline polymer characterized by excellent mechanical strength, wear resistance, and chemical stability.

Due to its high crystallinity, nylon exhibits superior toughness, fatigue resistance, and thermal performance. It can withstand demanding environments and often replaces metal in applications such as gears, fasteners, cable ties, fan blades, and pump parts.

The most common nylons used in injection molding include:

Nylon 6 (PA6)

Nylon 66 (PA66)

Nylon 12 (PA12)

Glass-fiber reinforced nylon (PA-GF)

Each grade has distinct mechanical and processing characteristics, allowing engineers to balance strength, flexibility, and moisture resistance for specific end uses.

Advantages of Nylon Injection Molding

Nylon is one of the most popular engineering plastics for injection molding because it combines moldability, performance, and cost-efficiency. Below are its major benefits explained in detail.

1. Low Melt Viscosity

Nylon melts easily and flows smoothly within the mold, even through thin sections or complex geometries.

Enables the production of thin-walled parts (as low as 0.7 mm).

Reduces injection pressure and ensures complete mold filling.

Shortens cycle times for high-volume production.

2. Excellent Chemical and Abrasion Resistance

Nylon resists a wide range of chemicals, including:

Dilute acids and alkaline solutions

Hydrocarbons, fuels, and oils

Organic solvents like alcohols and halogenated hydrocarbons

Its low coefficient of friction and high wear resistance make it ideal for parts that experience sliding or rotational motion, such as gears, bushings, and bearings.

3. High-Temperature Resistance

Nylon maintains mechanical integrity at elevated temperatures.

Standard nylon grades can operate continuously up to 120–150°C.

Glass-filled nylons withstand even higher temperatures before softening.
This property makes nylon suitable for automotive engine compartments and industrial machinery.

4. Fatigue and Impact Resistance

Nylon’s semi-crystalline molecular structure gives it excellent fatigue resistance, allowing it to endure repeated stress cycles without cracking or breaking.
Designing parts with generous corner radii further improves performance under cyclic loads.

5. Mechanical Strength Comparable to Metal

Nylon exhibits high tensile and flexural strength, enabling it to replace metal in many load-bearing applications.
Reinforcing nylon with glass fibers or mineral fillers increases rigidity and dimensional stability while reducing creep under load.

Nylon Injection Molding Design Guidelines

Proper part design ensures both dimensional accuracy and production efficiency. Below are nylon-specific design considerations.

1. Wall Thickness

Recommended: 0.030–0.115 in (0.76–2.92 mm)

Maintain uniform wall thickness to prevent sink marks and warping.

Gradual transitions (≤15%) between adjacent walls are ideal.

Avoid walls thicker than 6 mm, as they increase cooling time and may trap voids.

Nylon’s low melt viscosity allows thinner walls than many other thermoplastics while maintaining part strength.

2. Radii and Corners

Avoid sharp corners that create stress concentrations.

Minimum radius: 0.5 mm.

Optimal radius: ≈75% of nominal wall thickness for best fatigue performance.

3. Draft Angles

Nylon’s smooth surface and low friction allow for minimal draft.

0.5°–1° per side is recommended to ease ejection and shorten cycle times.

Flat surfaces (e.g., gears) can sometimes be molded with no draft.

4. Part Tolerances

Nylon has a higher shrinkage rate (0.5%–2%) than many plastics, making dimensional control challenging.

Accurate mold temperature management reduces variation.

Glass-filled grades exhibit lower shrinkage and improved stability.

Controlled moisture conditioning post-molding ensures long-term precision.

Nylon Material Properties

The following are typical material properties for several nylon grades:

Property	Nylon 11	Nylon 12	Nylon 46	Nylon 66	Nylon 66 30% GF
Density (g/cm³)	1.04	1.31	1.20	1.17	1.38
Linear Shrinkage (cm/cm)	0.0083	0.0069	0.019	0.0139	0.0044
Rockwell Hardness (R)	107	98	95	114	117
Tensile Strength (MPa)	37.1	46.1	73.9	72.5	155
Elongation at Break (%)	119	67	43	47	4
Flexural Modulus (GPa)	0.95	5.66	2.64	3.09	7.96
Drying Temperature (°C)	90	93	94	81	82
Melt Temperature (°C)	261	224	303	279	285
Mold Temperature (°C)	49	71	103	75	86

Key takeaway: Nylon’s balance of high tensile strength, hardness, and flexibility makes it ideal for load-bearing components. However, due to its hygroscopic nature, nylon must be dried thoroughly before processing.

Nylon Injection Molding Process Parameters

Controlling processing parameters ensures consistent part quality and dimensional accuracy.

1. Viscosity

Nylon has low melt viscosity, enabling fast mold filling through thin or intricate channels.

This reduces cycle times but requires careful pressure and speed control to prevent flashing.

2. Moisture Control

Nylon easily absorbs atmospheric moisture.

Excessive moisture causes voids, splay, and brittleness.

Optimal moisture content: 0.15–0.20%.

Dry nylon at 80–90°C for 3–6 hours before molding.

3. Temperature Control

Higher mold temperature → increased crystallinity and strength.

Too high (above 330°C) → risk of thermal degradation and discoloration.

Typical processing range:

Barrel temperature: 260–290°C

Mold temperature: 70–90°C

4. Injection Pressure

Typical range: 700–1400 bar (10,000–20,000 psi).

Low pressure → short shots, knit lines, poor surface finish.

High pressure → flash, warpage, or dimensional distortion.
Proper pressure profiling ensures uniform density and minimal internal stress.

5. Injection Speed

High injection speeds reduce cycle time and weld lines.

However, excessive speed can cause shear heating and burn marks.

Controlled ramp-up of speed is best for thin-walled nylon parts.

6. Gassing and Venting

Nylon molding generates gases during melt injection.

Poor venting causes voids, burns, and incomplete filling.

Provide vent depths around 0.02–0.04 mm near cavity edges.

7. Shrinkage

Typical range: 0.5–2%, depending on grade and cooling rate.

Controlled by:

Higher mold temperatures (reduce shrinkage).

Uniform wall thickness.

Glass reinforcement (minimizes warping).

Common Nylon Injection Molding Defects and Solutions

Defect	Possible Cause	Recommended Solution
Splay marks	Excess moisture	Pre-dry material properly
Flashing	Excess pressure or low clamp force	Adjust injection pressure, inspect mold fit
Warping	Uneven cooling or wall thickness	Optimize mold design and cooling layout
Short shots	Low injection speed or venting issue	Increase speed, improve venting
Discoloration	Overheating or degradation	Lower melt temperature, ensure material purity

Applications of Nylon Injection Molding

Nylon molded parts are used across numerous industries due to their combination of strength, toughness, and heat resistance.

Automotive: Gears, bushings, radiator fans, fuel line connectors

Electrical & Electronics: Cable ties, insulators, terminal housings

Consumer Goods: Power tool housings, appliance components

Industrial Equipment: Bearings, rollers, mechanical fasteners

Aerospace: Lightweight interior fittings, brackets, clips

Best Practices for Successful Nylon Injection Molding

Store nylon pellets in airtight containers to prevent moisture absorption.

Always dry material before molding.

Maintain uniform cooling to minimize warping.

Use glass-filled grades for high-strength or precision applications.

Apply controlled temperature and pressure profiles during molding.

Conclusion

Nylon injection molding combines the strength of engineering plastics with the versatility of thermoplastics. When processed correctly, nylon delivers exceptional performance, durability, and precision, making it a preferred material for both industrial and consumer applications.

Proper control of moisture, temperature, and pressure, along with intelligent design practices, ensures high-quality nylon parts that can even replace metal components.

FAQs

What is the best type of nylon for injection molding?
Nylon 6 and Nylon 66 are the most commonly used types. Nylon 66 offers higher strength and temperature resistance, while Nylon 6 provides better surface finish and flexibility.
Why must nylon be dried before injection molding?
Because nylon is hygroscopic, it absorbs moisture from the air. Moisture in the resin can cause bubbles, splay, and degradation during molding.
Can nylon replace metal parts in mechanical assemblies?
Yes. With glass-fiber reinforcement, nylon can achieve tensile strength comparable to aluminum, making it a cost-effective lightweight alternative.
What are the common challenges when molding nylon?
Key challenges include moisture absorption, shrinkage, warping, and maintaining tight tolerances due to high shrinkage rates.
How do you reduce shrinkage in nylon injection molding?
Use higher mold temperatures, uniform wall thickness, and glass-filled grades. Controlled cooling also helps prevent warpage.

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