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Steel rollers are heavy, prone to rust, and create maintenance headaches during replacement. Nylon conveyor rollers solve these issues while being more cost-effective. However, machining nylon requires specialized expertise as it deflects, absorbs coolant, and requires specific cutter geometries to avoid melting and ensure clean results.
Nylon 6/6 (PA66) is the standard material for conveyor rollers, offering toughness, excellent wear resistance against steel frames, and continuous operation up to 80°C. For food processing or wet environments, we recommend Delrin/Acetal since nylon absorbs moisture and swells - a 50.00mm dry roller can become 50.08mm after washdown, potentially causing belt tracking issues.
Maintaining concentricity is critical for conveyor rollers. Our between-centers turning process with live tailstock support ensures 300mm rollers maintain concentricity within 0.05mm, eliminating vibration that damages conveyor belts. Cycle time for a 300mm nylon roller is approximately 4 minutes.
Nylon rollers often operate quieter than steel, but surface finish optimization is crucial. We target Ra 1.6-3.2 on rolling surfaces for proper belt traction without abrasion, and can add custom groove patterns for specific grip requirements.
Key Features
Nylon 6/6 (PA66): High wear resistance, low friction coefficient, and impact toughness suitable for heavy loads and continuous operation
Delrin Option Available: For moisture-critical environments where nylon's water absorption would cause dimensional instability
Concentricity Control: Turned between centers with live tailstock, total runout within 0.05mm on rollers up to 600mm length
Bearing Seat Precision: Bore tolerance H7 for standard bearing fit, with optional press-fit or slip-fit geometry
Surface Finish Optimized: Ra 1.6-3.2 on rolling surface for belt traction, Ra 0.8 on bearing seats for accurate fit
Custom Groove Patterns: Diamond knurl, herringbone, straight groove, or plain surface available for specific belt traction requirements
Assembly Option: Complete roller assembly with pressed bearings and installed shafts for ready-to-install components
Manufacturing Process
Material Selection: Confirm nylon grade based on load, speed, temperature, and moisture exposure requirements
CNC Turning: Mount between centers, rough turn OD, finish turn to final diameter with surface finish control
Secondary Machining: Drill and tap axle holes, mill keyways or set screw flats as required
Deburring: Remove machining burrs using low-speed tools suitable for heat-sensitive nylon
Dimensional Inspection: Comprehensive checking of diameter, length, runout, bore size, and groove depth
Packaging: Individually wrapped protection with custom labeling for material grade and part identification
Frequently Asked Questions
Nylon or Delrin -- how do I choose for a conveyor roller?
For dry, room temperature environments, nylon offers better toughness and cost-effectiveness. For moisture, washdown, or high humidity applications, choose Delrin as it doesn't absorb water and maintains dimensional stability. Nylon can swell 1-2% when saturated, affecting bearing fits and belt tracking.
Can you make crowned rollers (barrel-shaped) for belt tracking?
Yes, we regularly produce crowned rollers for center-driven conveyors. We program the crown profile directly into CNC turning cycles, typically applying 0.5-1mm crown on 100mm diameter rollers. Simply specify your crown requirements.
What's the maximum roller length you can machine?
Our between-centers setup handles up to 1,200mm. For longer requirements, we recommend two-piece construction with steel shafts and nylon sleeves - a common solution for extended conveyor systems.
Do nylon rollers handle heavy loads?
Nylon 6/6 provides approximately 500kg load capacity on a 50mm diameter roller at 200mm span. For heavier loads, we can increase diameter, add steel cores, or use reinforced nylon (glass-filled) which doubles capacity.
Can you add bearings and shafts before shipping?
Yes, we stock standard 6200-series bearings and can press-fit them into bearing seats. We provide complete assembled roller units ready for installation into conveyor frames.
How does nylon hold up in cold environments?
Nylon becomes brittle below -20°C. For freezer or cold storage applications, Delrin maintains ductility down to -40°C. UHMW-PE is another cold-environment option, though with lower load capacity.