How Is a Nylon Shuttle Made?

How Is a Nylon Shuttle Made?

You take a nylon shuttle out of the tube and start your training or match. You’ve probably done this many times, but have you ever wondered how a badminton shuttleis actually made? Below, we explain the manufacturing process step by step.

Step 1: Creating the Mold for the “Skirt”

The production process starts with a precise mold. This mold determines the shape of the shuttle’s skirt (the synthetic “feathers”).

The entire skirt is produced as one single piece. This ensures:

• consistent flight
• minimal variation between shuttles
• high durability

Even small deviations in the mold can affect the shuttle’s stability in the air.

Step 2: Nylon Injection Molding

In an advanced machine, liquid nylon is injected into the mold under high pressure. This process is called injection molding.

During this phase:

• the shuttle receives its final shape
• the color can be determined
• the structure becomes fully sealed

Nylon is strong, flexible and wear-resistant. That is why nylon shuttles last much longer than feather shuttles, especially during training sessions.

Step 3: Cooling and Hardening

Once the skirts leave the machine, they are still warm.

They must cool down in a controlled way to:

• maintain their shape
• reduce internal stress
• prevent deformation

Proper cooling is essential for consistent flight quality.

Step 4: Producing the Cork Base

The base of a nylon shuttle consists of natural cork.

Cork is important because:

• it creates a realistic impact feel
• it ensures correct balance
• it contributes to natural shuttle response

A plastic casing is placed around the cork to protect it and allow a strong connection to the nylon skirt.

Step 5: Assembly

In the final stage, the nylon skirt and cork base are assembled.

In a specialized machine:

• both components are precisely aligned
• a small amount of adhesive is applied
• the parts are firmly joined together

Perfect alignment is crucial, as even small errors influence flight performance.

Why This Process Matters

The way a nylon shuttle is manufactured determines:

• durability
• flight stability
• impact feel
• suitability for training or recreational play

Higher quality shuttles use more precise molds and better materials, resulting in more consistent performance.

Nylon Shuttle vs Feather Shuttle

A short comparison

Nylon shuttle

• Lasts longer
• Ideal for training sessions
• Less sensitive to temperature
• Consistent speed

Feather shuttle

• Natural flight trajectory
• Used in competition
• More sensitive to wear

Do you train several times per week? Then a high-quality nylon shuttle is often the most durable choice.

Which Nylon Shuttle Suits You?

Not every badminton player has the same needs.

Do you play recreationally or train intensively? Are you looking for maximum durability or a flight performance closer to a feather shuttle?

At KW FLEX, we are happy to help you choose the right badminton shuttle for your level and usage.

Summary: How a Nylon Shuttle Is Made

• A precise mold is created for the skirt structure
• Nylon is injected into the mold under high pressure
• The skirt cools down in a controlled way
• The cork base is produced with a protective plastic casing
• The base and skirt are assembled mechanically

A technical process with one goal: a stable, durable and reliable shuttle.

Need Advice on Badminton Shuttles?

Not sure which shuttle suits your training sessions or matches?

• Explore our range of nylon shuttles
• Or ask for personal advice from our specialists in our badminton shop

So you always play with the right shuttle for your level.