From military gear to outdoor apparel: in an interview with David Gatti, European Business Manager at CORDURA® Advanced Fabrics, we check how their yarn plays a crucial role in creating high-performance materials.
With over 55 years of innovation, CORDURA® offers a diverse range of over a dozen fabric technologies, including woven nylon ballistic fabric design to use in military body armor, and Combat Wool™ fabric used in military uniforms.
Let’s start from scratch.
The process of making CORDURA® fabrics begins with the production of essential chemicals, which serve as the building blocks for the nylon yarn. Once these chemicals are manufactured, they are processed to create chips, which are then melted down to form nylon 6,6 yarn. After the yarn is created, it is sent to fabric mills where it is woven into various types of fabrics tailored for specific applications. These finished fabrics undergo rigorous testing in both internal and external labs to assess performance metrics such as tear strength, tensile strength, and abrasion resistance. Only those that meet Cordura’s stringent standards are certified, enabling manufacturers to label their products as CORDURA® fabrics. This comprehensive process underscores CORDURA®’s commitment to quality and innovation, resulting in high-performance fabrics used across a wide range of products, from socks and backpacks to body armor.
”We do filament yarns and we do fibers. The filaments usually are used to create fabrics that are 100% nylon fabrics – nylon 6,6 fabrics, that are being used for ballistic vests, and backpacks. Whereas for garments, we use fibers that are blended with others. [They] can be blended with cotton, can be blended with aramids, can be blended with different kinds of other fibers in order to create fabrics for uniforms, combat shirts, base layers; any kind of garments,” says Gatti.
CORDURA® Ballistic Fabric is engineered for durability and performance, constructed from high-tenacity nylon 6,6 filament yarns that enhance tear and abrasion resistance. The fabric features a tightly woven 2×2 basket weave, which contributes to an optimal strength-to-weight ratio while providing excellent protection against wear and tear. Its high-tenacity bright filament, typically greater than 420D, gives the fabric a noticeable luster and sheen, and it can be found in both coated and laminated versions for additional durability. CORDURA® Ballistic Fabric is commonly used in a range of products, including backpacks, luggage, footwear, and motorcycle gear, making it well-suited for demanding environments where resilience is essential.
CORDURA® actively engages with stakeholders across different markets to gather feedback on their products. Major sectors include the military, workwear, and outdoor industries.
”We talk to fabric mills, people making fabrics. But we also have people coming to us talking about they want to make a new backpack, they want to make a new garment.”
This engagement allows CORDURA® to develop new products, prompting discussions about how their range of fabrics can meet these requirements.
Yarn is like carrots and radishes.
Searching for more sustainable and efficient solutions, CORDURA® created an innovative way to produce yarn that limits the emission of CO2 and waste of water and energy.
”Initially, that kind of yarn was kind of a natural color. People would weave it, dye the fabric, and then make the product. Now what we do is when we produce the yarn, we put the color inside the yarn,” explains Gatti. With the new technology, when the chips are melted, color pigments are incorporated into the mixture. This allows for a uniform blending of the pigments and the nylon, resulting in a yarn that emerges with color integrated throughout. This method is not only more sustainable but also makes the material more durable and resistant to abrasions.
”To give you an example, you know a radish and a carrot? The radish, when you cut it, it’s red on the outside, it’s white inside. When you cut the carrot, it’s orange outside and orange inside. So the new technology is the carrot. It’s orange outside, orange inside. You can scrap it and you will always have the color.”
As Gatti acknowledges, an increasing number of people are recognizing the benefits of these innovations, particularly in terms of enhanced product performance and sustainability. The new processes require significantly less water and energy, resulting in substantial CO2 savings. As a result, many countries are prioritizing the development of more efficient manufacturing methods that achieve the same outcomes while minimizing environmental impact. This shift reflects a broader trend toward creating products that are not only high-performing but also more environmentally friendly. Looking ahead, CORDURA® is well-positioned to lead in this evolving landscape. By continuously refining their technologies and focusing on sustainable practices, they can meet the growing demand for durable fabrics that also prioritize ecological responsibility.
