For manufacturers and product developers, integrating the MOLLE (Modular Lightweight Load-carrying Equipment) or PALS (Pouch Attachment Ladder System) webbing grid into a product requires more than just understanding its concept. It requires following specific dimensional and construction guidelines. These standards help ensure that gear works well with other compatible items, holds up during use, and meets user needs. Products that do not meet these guidelines can be hard to attach to and may not perform reliably in demanding situations.
This guide covers the main technical standards to keep in mind when producing gear with MOLLE or PALS webbing.
The Importance of Webbing Spacing
Precise spacing forms the basis of the MOLLE and PALS system. It allows attachments from different brands to fit together without issues. Manufacturers must measure these distances accurately.
The vertical spacing between adjacent horizontal rows of webbing is 1 inch (25.4 mm). This measurement refers to the open gap between the bottom edge of one row and the top edge of the next row.
Along each horizontal row, stitches create segments for attachments.
The horizontal spacing from the center of one stitch to the center of the next stitch is 1.5 inches (38.1 mm).
These measurements create a consistent grid. A deviation of even a few millimeters can prevent pouches or accessories from weaving through the webbing properly.
side molle webbing of a black plate carrier vest 
Webbing Specifications and Materials
The webbing material must have the right dimensions for strength and fit.
The standard width of the webbing is 1 inch (25.4 mm). Webbing wider than this will not pass through the slots on standard MOLLE attachments.
For military-grade gear, use Type III nylon webbing, as specified in A-A-55301. This material offers a breaking strength of at least 1,200 pounds and low stretch. Polyester webbing can work if it matches these properties, but it must resist deformation under heavy loads.
Stitching: Ensuring Strength and Durability
Stitching secures the webbing and bears the weight of attached items. Weak stitching often causes failures in MOLLE gear.
The standard stitch pattern is a box with an “X” bartack at each 1.5-inch interval. This design spreads out the load better than straight stitches and resists pulling apart.
Use high-tenacity bonded nylon thread with a thickness of TEX 70 or greater. This thread holds up against friction and repeated stress, unlike standard polyester thread.
For the bartack, aim for 4 to 5 stitches per side of the box, with a tight “X” pattern in the middle. This density prevents unraveling over time.
The Role of Backing Material and Attachments
The fabric or base that the webbing attaches to plays a key part in overall strength.
Sew the webbing onto a durable fabric such as 1000-denier Cordura nylon. A weak base can tear at the stitches, even with strong sewing.
In laser-cut MOLLE designs, the grid is cut directly into padded or laminated materials. These slots must measure exactly 1 inch high by 1.5 inches wide, with sealed edges to avoid fraying. The base material needs extra reinforcement here, as stress concentrates at the cuts.
Following Official Standards
To meet military requirements or build trust in the market, follow established specifications. The U.S. military’s original guidelines appear in documents like GL/PD 10-94 for the MOLLE system.
For webbing details, refer to A-A-55301, which outlines material and performance tests for nylon webbing used in load-carrying gear.
These standards include pull tests and abrasion checks to confirm reliability. You can access the A-A-55301 document here for full details on requirements.
Risks of Not Meeting Standards
Failing to follow these guidelines can lead to several problems.
- Gear may not connect easily with items from other makers, limiting its usefulness.
- Users might find attachments too tight or loose, leading to complaints and returns.
- Under load, poor materials or stitching can cause rips or failures, which may compromise safety.
Work with an Experienced MOLLE Gear Manufacturer
Building MOLLE and PALS webbing into products takes careful attention to detail and skilled production. Our company has manufactured and supplied tactical, military, and outdoor gear since 2009.
We produce customized items such as bags, vests (including dog vests and harnesses), modular pouches, soft gun cases, belts, slings, holsters, and more. We follow these standards to deliver accurate, durable panels that work seamlessly with other gear and support your brand’s reputation.
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