How Duct Tape is Made

Duct tape is a pressure-sensitive tape that is coated with polyethylene on one side and fabric on the other. The combination makes the tape adaptable and user friendly. The fabric gives duct tape the strength and at the same allows it to be easily torn when needed. It was initially designed for use in air duct applications, but today it is widely used for numerous purposes, especially in household repair jobs.

It is commonly believed that duct tape was created and perfected by Permacell, a division of Johnson and Johnson, during World War II in the 1940s. They developed a unique process to combine multiple layers of adhesive onto a polyethylene coated cloth backing. The raw materials used in making duct tape include cotton mesh, polyethylene coating and adhesive compound.

Duct tape goes through a series of manufacturing processes. The rubber-based adhesive is combined in a mixer known as a Branbury-type mixer and then heated and mixed until they are melted and homogenous. Ingredients like tackifying agents, viscosity modifiers, antioxidants, and other adjuncts are added to the blend tank as specified in the formulation. After this, the adhesive and the fabric are combined using sophisticated coating equipment. The cloth is then fed into the coating machine through another set of rollers to transfer the adhesive to the cloth. Once the coating process is completed, the tape is cut to its final size. These packages are then boxed and marketed for shipping.

Duct tape has several grades which are designed for specific applications. The grade is determined by the combination of adhesive type and the strength of the cloth fabric. Duct tape also goes through a series of standard tests described by the American Society for Testing and Materials.