Development of Nylon 66 Coated Motorcycle Jacket (Comprehensive Design Project)
Developed a lightweight, durable, and cost-effective motorcycle jacket for improved rider safety, bridging the gap between heavy protective gear and lightweight jackets with limited protection. Built from Nylon 66 basket weave fabric coated with Styrene Butadiene Rubber (SBR) in a four-layer composite structure that improves abrasion resistance, tear strength, and overall durability while keeping the garment commercially viable. Project Description: A technical design was developed using a four-layer composite structure with two Nylon 66 fabric layers and two SBR coating layers. The jacket includes shoulder, elbow, and back reinforcement panels for impact and abrasion protection. It also features a stand collar with snap closure, centre front zipper, side welt zipper pockets, and adjustable cuff and waist tabs. Reinforced seams, bonded nylon thread, and protective topstitching support strength and durability across high-stress areas of the garment. Solution: Nylon 66 basket weave fabric was paired with Styrene Butadiene Rubber (SBR) coating in a four-layer composite to balance protection with weight and cost. Targeted reinforcement panels, considered seam construction, and rider-focused fit were combined with a full tech pack covering measurements (XS–XL), BOM, construction details, and material/process flow, so the design is production-ready for commercial manufacture. Conclusion: The project delivers a practical protective jacket that balances safety, comfort, affordability, and durability. The Nylon 66 and SBR composite structure is intended to reduce abrasion damage, tearing, cutting, and minor impact-related injuries while maintaining a clean fitted rider silhouette suitable for commercial use. Performance was validated through abrasion, impact, tear, bursting strength, and impact-cut resistance testing.
