Who invented nylon staple fiber?

Acrylic staple fiber is a synthetic fiber made primarily from polyacrylonitrile (PAN). It is soft, wear-resistant, lightfast, and wrinkle-resistant, often used as a wool substitute in sweaters, blankets, and other textiles. It was invented in the 1940s by chemists at DuPont in the U.S., initially branded as "Orlon". As one of the key synthetic fibers developed after nylon, acrylic is produced by polymerizing petrochemical materials, spinning them into filaments, and then cutting them into short fibers for textile processing.

Evolution History

The development of nylon staple fiber originated in the 1950s, derived from DuPont's pioneering nylon filament technology. Following breakthroughs in high-speed spinning technology and differentiated product development in the 1970s, the industry achieved global expansion during the 1990s with the rise of Asian production capacity. Since the 21st century, China has become a major global production base, while innovations in recycled nylon and bio-based nylon technologies have driven green transformation in the sector. Today, ultra-fine denier and functional nylon staple fibers are widely used in high-end textiles, automotive interiors, and smart wearable applications, with global annual production capacity reaching 1.8 million metric tons.

Physical Characteristics

Nylon staple fiber exhibits outstanding physical properties: high tensile strength (4.5-8.5 cN/dtex) and exceptional abrasion resistance (10+ times higher than cotton), with 95%-100% elastic recovery. Its melting point varies by type (PA6: 215-220°C; PA66: 255-265°C), and it has a density of 1.14 g/cm³ (lighter than polyester) along with moderate moisture absorption (4-4.5% regain). These characteristics make it ideal for carpets, sportswear, and industrial fabrics.

Physical Properties 
Nylon staple fiber features high tensile strength (4.5-8.5 cN/dtex) and outstanding wear resistance, with 95%-100% elastic recovery. Its melting point varies by type (PA6: 215-220°C; PA66: 255-265°C), and it has a density of 1.14 g/cm³ with moderate moisture absorption (4-4.5% regain). Additional advantages include anti-static properties and fatigue resistance, making it ideal for high-end textiles and industrial applications.

Development Prospects

Driven by the textile industry's shift toward high-performance and sustainable solutions, nylon staple fiber—with its exceptional strength, elasticity, and abrasion resistance—is poised to expand its applications in premium sportswear, smart wearables, and automotive interiors. Advancements in bio-based and recycled nylon technologies will accelerate green transformation, while ultra-fine denier and multifunctional composite fibers (e.g., antibacterial, conductive) will further enhance value-added potential, promising significant market opportunities.

Applications of Nylon Staple Fiber Across Industries

1. Textile & Apparel Industry
High-end Clothing
• Sportswear (elasticity & abrasion resistance requirements)
• Swimwear/Yoga wear (chlorine-resistant & quick-drying properties)
• Cashmere-like knitwear (soft and fluffy texture)

Hosiery
• Utilizes high elasticity (95%+ recovery rate) and wear resistance

2. Home Furnishings & Textiles
Carpets/Blankets
• Commercial carpets (abrasion resistance >50,000 cycles)
• Electrostatic flocking carpets (PA6 staple fiber preferred)

Decorative Fabrics
• Curtains (UV-resistant modified grades)
• Upholstery fabrics (anti-pilling treatment)

3. Industrial Textiles
Automotive Industry
• Seat fabrics (flame-retardant grades meeting FMVSS302 standards)
• Seatbelts/Airbags (high-strength PA66 staple fiber)

Filtration Materials
• Industrial filter cloth (acid/alkali-resistant grades)
• Melt-blown layer reinforcement for medical masks

4. Industrial Manufacturing
Paper Machine Clothing
• Wet-process papermaking (hydrolysis-resistant PA6 grades)

Polishing Materials
• Nylon polishing wheels (0.5-3D ultra-fine staple fiber)

Composite Materials
• Reinforcement blended with fiberglass

5. Emerging Technology Fields
Smart Wearables
• Conductive nylon staple fiber (embedded sensors)

Medical & Healthcare
• Absorbable sutures (modified PA4/PA6)
• Antibacterial wound dressings (silver-ion composite staple fiber)