My wife makes flags out of nylon for our local high school band. She has mastered a technique that allows the nylon to be cut to size without the need to sew finishing seams. If nylon is cut with a scissors and the edge left unfinished it won’t be long before the wind starts to make the material run and fray.
The concept is similar to that of cutting a nylon strap or rope and putting a match or lighter to the frayed end “melting” a finished edge. This technique melts a finished edge to the nylon that will never run or fray. Never. It’s a little more trickery with nylon vs. cutting and melting a strap, but here’s what you need:
1.Standard electric wood burner available at hobby stores, Wal-marts, Target etc. $7-$12 range.
2.Metal straightedge.
3.Tempered glass (I use a recycled glass door from the front of a stereo cabinet) about 20” X 18”. If it is at least as long as your straightedge its big enough.
-Mark edge to be cut.
-Lay material flat on glass
-Align straightedge with marked edge to be cut to hold fabric in place.
-With pre-heated wood burner trace fabric along straightedge in a smooth intentional motion.
It should separate cleanly with a “cauterized” edge. Different weights of nylon and differences in how hot the wood burner are will affect how the fabric separates. With a couple of practice cuts first, it won’t be long before you get the feel for the speed needed to make a clean cut.
I have cut a tarp and other projects made of “melt-able” fabrics and once mastered saves time and holds up better than a finished seam.