Hypalon

Hypalon is a type of synthetic rubber known for its exceptional resistance to chemicals, UV radiation, abrasion and extreme temperatures. The material was originally developed by DuPont and became a standard in professional and military equipment thanks to its outstanding strength and long service life. Hypalon is commonly used as a reinforcement material in high-stress areas where minimal wear and maximum durability are required. Although the trademark Hypalon® is no longer officially produced (DuPont ended production of the original formulation), today’s manufacturers use functionally equivalent modern versions that retain the same characteristics and are still widely referred to as “Hypalon” in tactical gear. In practice, Hypalon is an extremely strong, durable and lightweight reinforcement material used on plate carriers, cummerbunds, pouches and backpacks. Soldiers, special forces and demanding airsoft players value it for its longevity, low weight and abrasion resistance. The brand Helikon-Tex uses it in its premium products, such as the GUARDIAN system.

Use of Hypalon in military and tactical equipment

Reinforcement of MOLLE panels – used in modern plate carriers as reinforcement of laser-cut panels, ensuring they do not tear or crack.
Straps and mounting points – extremely abrasion-resistant, ideal for high-stress components (handles, attachment points, MOLLE loops).
Handles, pull tabs, rescue loops – used where the material must withstand high tensile loads.
Protective zones on backpacks, pouches and carriers – prevents tearing and significantly increases durability even in harsh conditions.

Advantages of Hypalon

Excellent resistance to abrasion, tearing and cutting.
High chemical resistance.
Superior UV resistance – does not become brittle over time.
Resistant to extreme temperatures.
Low weight combined with high strength.

Disadvantages of Hypalon

Higher price compared to cheaper synthetic fabrics.
More difficult to sew; often requires laser-cut manufacturing.