Nylon Stock Sizes & Specifications
Nylon is stocked in four standard forms — sheet/plate, rod, tube, and hex bar — with size ranges that differ significantly between cast and extruded production. Understanding the available dimensions before designing a part avoids ordering custom billet or settling for incorrect stock. This page covers standard stock dimensions, dimensional tolerances, and the material standards that govern nylon engineering shapes.
TL;DR
- Cast plate: up to 24" × 96", 4" thick — the largest nylon sheet form
- Cast rod: ¼" through 12" diameter; extruded rod typically tops out at 4"
- Tube: cast nylon tube from 1" to 12"+ OD with varied wall thicknesses
- Hex bar: extruded Nylon 6/6 hex, ½" through 2½" across-flats
- Governing standards: ASTM D5989 (cast nylon), MIL-PRF-46060, and manufacturer specifications
- Tolerances on cast stock are wider than extruded — plan accordingly for close-fit parts
Sheet and Plate
Cast Nylon 6 Plate
Cast plate is the go-to for heavy structural nylon applications: large gear blanks, thick wear pads, heavy-duty chocks, and large sheave bodies that must be machined from the solid.
| Thickness | Standard Width × Length | Notes |
|---|---|---|
| ½" | 24" × 48", 24" × 96" | Full sheet |
| ¾" | 24" × 48", 24" × 96" | Full sheet |
| 1" | 24" × 48", 24" × 96" | Full sheet |
| 1½" | 24" × 48", 24" × 96" | Full sheet |
| 2" | 24" × 48", 24" × 96" | Full sheet |
| 3" | 24" × 48" | Standard; 96" length on request |
| 4" | 24" × 48" | Standard; larger sizes on request |
Thickness tolerance: ±10% on cast plate is typical for standard stock. For precision applications, specify a machined-one-side (MOS) or machined-two-sides (MTS) finish to achieve ±0.010" or better.
Surface condition: Cast plate arrives with a smooth skin. The skin is slightly harder and denser than the interior due to contact with the mold face. For applications where surface properties are critical (bearing faces, precision fit surfaces), machine off the skin rather than using the as-cast surface.
Extruded Nylon 6/6 Sheet
Extruded sheet is produced in thinner sections with tighter tolerances than cast plate. Standard range:
| Thickness | Standard Width × Length |
|---|---|
| 1/16" | 24" × 48" |
| 1/8" | 24" × 48", 48" × 96" |
| ¼" | 24" × 48", 48" × 96" |
| 3/8" | 24" × 48", 48" × 96" |
| ½" | 24" × 48" |
| ¾" | 24" × 48" |
| 1" | 24" × 48" |
Thickness tolerance: ±5% for extruded sheet under 1" thick.
For plate thicknesses above 1", cast Nylon 6 is the preferred source. Extruded nylon in heavy sections is available but carries higher residual stress and is less commonly stocked. Cast plate above 1" thick is lower-stress and often more cost-effective.
Rod
Cast Nylon 6 Rod
Cast rod covers the large-diameter range where no extruded equivalent is practical. Standard stocked diameters:
| Diameter Range | Length | Grade Availability |
|---|---|---|
| ½" – 2" | 24"–48" billets | Natural, Nylatron GS, Nyloil |
| 2" – 4" | 24"–36" billets | Natural, Nylatron GS |
| 4" – 6" | 24"–36" billets | Natural, Nylatron GS |
| 6" – 8" | 18"–24" billets | Natural |
| 8" – 10" | 12"–24" billets | Natural |
| 10" – 12" | 12"–18" billets | Natural; custom pour on request |
Diameter tolerance: Cast rod is produced to a diameter tolerance of approximately +0.060"/−0.000" on sizes up to 4"; larger diameters may have wider production tolerance. Always confirm machined clearance is sufficient before planning finish operations.
Roundness: Cast rod can exhibit minor ovality, particularly in larger diameters. For precision turning, mount between centers and rough-turn to clean up the OD before finishing.
Extruded Nylon 6/6 Rod
Extruded rod is available in longer continuous lengths and tighter diameter tolerances. Standard stock:
| Diameter | Standard Length | Diameter Tolerance |
|---|---|---|
| ¼" | 6' or 12' | ±0.005" |
| 3/8" | 6' or 12' | ±0.007" |
| ½" | 6' or 12' | ±0.007" |
| ¾" | 6' or 12' | ±0.010" |
| 1" | 6' or 12' | ±0.010" |
| 1¼" | 6' or 12' | ±0.010" |
| 1½" | 6' or 12' | ±0.012" |
| 2" | 6' or 12' | ±0.015" |
| 2½" | 6' | ±0.020" |
| 3" | 6' | ±0.020" |
| 4" | 6' | ±0.030" |
Note: Extruded rod above 3" diameter is less commonly stocked. Above 4", switch to cast Nylon 6 for standard availability.
Tube
Cast nylon tube is used for machined roller bodies, bushing sleeves with heavy walls, and sheave blanks with pre-formed bores. Tube reduces material removal and machining time vs. boring from solid rod.
Standard Cast Nylon 6 Tube Sizes
| OD | Wall Thickness Range | Notes |
|---|---|---|
| 1" OD | 3/16"–¼" wall | Standard light-duty bushing |
| 1½" OD | ¼"–3/8" wall | Standard |
| 2" OD | ¼"–½" wall | Standard roller/bushing |
| 2½" OD | 3/8"–½" wall | Standard |
| 3" OD | ½"–¾" wall | Standard sheave/roller |
| 4" OD | ½"–1" wall | Standard |
| 5" OD | ¾"–1" wall | Standard |
| 6" OD | 1"–1½" wall | Standard |
| 8" OD | 1"–2" wall | Available |
| 10"+ OD | Custom wall | Custom pours; consult supplier |
Length: 24"–48" sections standard; larger ODs come in shorter lengths. ID is cast slightly undersize — plan for 0.030"–0.060" bore stock removal. Some suppliers offer finished-bore tube — confirm availability with your distributor.
Hex Bar
Extruded Nylon 6/6 hex bar is produced for machined fasteners (nuts, standoffs, fittings, valve handles) where a hex broach or held hex is required.
| Across-Flats (A/F) | Approximate Diameter | Standard Length | Notes |
|---|---|---|---|
| ½" A/F | 0.577" dia | 6' | Standard fastener stock |
| 9/16" A/F | 0.650" dia | 6' | Standard |
| ¾" A/F | 0.866" dia | 6' | Standard |
| 1" A/F | 1.155" dia | 6' | Standard |
| 1¼" A/F | 1.443" dia | 6' | Standard |
| 1½" A/F | 1.732" dia | 6' | Standard |
| 2" A/F | 2.309" dia | 6' | Standard |
| 2½" A/F | 2.887" dia | 6' | Standard or custom |
Tolerance: Hex A/F dimension is held to ±0.010"–0.020" depending on size. Nylon hex is not precision-ground — if close A/F tolerance is needed, machine from round rod.
Material Standards
| Standard | Scope |
|---|---|
| ASTM D5989 | Cast Nylon 6 — property requirements (primary spec for cast shapes) |
| ASTM D6779 | Nylon 6/6 rod and bar — property classification for extruded stock |
| MIL-PRF-46060 | Military cast nylon — dimensional and mechanical requirements |
| FDA 21 CFR 177.1500 | Food-contact compliance — natural unfilled grades |
| RoHS / REACH | EU environmental compliance — confirm with supplier on filled grades |
MIL-PRF-46060 distinguishes Type I (Nylon 6) from Type II (Nylon 6/6). Confirm the correct type and production method (cast vs. extruded) before ordering to spec.
Ordering and Cut-to-Size
Standard nylon stock is available in full sheets, full rods/bar lengths, and cut-to-size pieces. For machined parts sourced from cut-to-size stock:
- Sheet cutting: waterjet and band-saw are the standard cut methods. Waterjet provides clean edges and tight dimensions on complex profiles. Band-saw is faster for rectangular blanks.
- Rod cut-to-length: cold-saw or band-saw. Allow 1/8"–3/16" facing stock on each end for a clean finish cut.
- Minimum wall for bored tube: maintain at least 3/16" finished wall in unfilled nylon; glass-filled grades require 1/4" minimum due to brittleness.
For full machining parameters, speeds, and feeds, see the nylon machining guide.
For grade-specific stocking information, see the nylon grades page or the full nylon material overview.
Request a quote on nylon stock — sheet, rod, tube & hex
Request a Quote →Related Guides
More related guides
Cross-cluster suggestions to help shoppers and engineers explore adjacent topics:
Applications
Industries
Compare to other materials
Frequently asked questions — Nylon FAQ