Introduction: Choosing the Right Frame Material Isn’t Just a Technical Decision—It’s a Business One

When it comes to producing sports sunglasses, most people focus on the design first—shape, lenses, colors. But the frame material you choose? That’s where the real difference is made.

The truth is, the material decides how the frame feels, how long it lasts, and whether customers come back. Pick the wrong one, and you’ll hear things like:

• “It broke after one drop.”
• “Too heavy for sports.”
• “The paint started peeling after one week.”

We’ve seen it all.

At Eyewearbeyond, we’ve manufactured thousands of styles for brands worldwide using PC, TR90, and Nylon. Each one has its strengths—and its hidden downsides. The key is matching the material to your product’s actual purpose.

In this guide, we’re not going to throw a bunch of technical terms at you.
We’re going to break it down like you’re choosing stock for your next production run:

• What’s most flexible?
• What’s fastest to produce?
• What gives you the best profit margins?
• What fits your brand level?

If you’ve ever asked “What’s better—PC, TR90, or Nylon?” this article will help you answer that like a pro.

Let’s get into it.

Overview of the Three Main Materials: PC, TR90, and Nylon

Before we compare them side by side, let’s quickly go over what each material actually is—without the complicated science stuff.

🟩 PC (Polycarbonate)

This is the old-school, go-to plastic for many eyewear factories.
It’s:

• Rigid and strong, but not very flexible
• Easy to shape, great for clean lines and firm structure
• Affordable, with short production cycles

PC frames are great if you’re looking for:

• A basic sport frame with clear structure
• Strong support for thicker lenses
• A lower-cost option to test the market

But here’s the thing: they can snap if stressed too much, and they’re not the most comfortable for long wear.

🟦 TR90

TR90 is the lightweight hero of the sports eyewear world.

Originally developed in Switzerland, this material is:

• Super flexible—it bends instead of breaks
• Feather-light—perfect for all-day wear
• Fast to mold and color—ideal for fast-moving SKUs

It’s not fancy, but it’s comfortable, safe, and cost-effective.
TR90 frames are a favorite for:

• Urban sports
• Youth sunglasses
• DTC brands who want “nice feel, affordable price”

The only downside? It may not look or feel “premium” enough for higher-end collections.

🟥 Nylon (PA12)

Now we’re in the high-performance category.

Nylon is used in:

• Military gear
• Extreme sports equipment
• Pro-level sunglasses for cyclists, climbers, etc.

Why? Because it’s:

• Insanely tough, but still flexible
• Resistant to cold, heat, sweat, and drops
• Comfortable thanks to its slight elasticity

It feels more “premium” in hand, has a softer matte look, and performs well in almost any condition.
But: it’s harder to mold, takes longer to produce, and mold costs are higher.

Think of it this way:

• PC is your go-to for function and price.
• TR90 is your everyday workhorse for comfort and speed.
• Nylon is your top-tier option when you need a frame that can go through hell and survive.

Performance Comparison in Real Use

Choosing a material isn’t just about what it looks like on paper—you need to know how it holds up when real people actually wear it. Especially in sports sunglasses, comfort, flexibility, and durability can make or break your product.

Here’s how PC, TR90, and Nylon perform in real-world use cases:

🔍 Quick Comparison Table

🏃‍♂️ Use Case Breakdown

• PC:
  Good for daily commuter frames, fashion-function hybrids, or value-line sport styles. Just make sure the design isn’t too thin.
• TR90:
  Perfect for light sport activity like jogging, cycling, or casual outdoor use. Feels great on the head, won’t snap under pressure.
• Nylon:
  Built for serious sports use—trail running, skiing, tactical use, extreme heat/cold. Frames will last and perform under pressure.

🎯 Real Talk from the Factory Floor

• If your customers are occasional users or want a good deal, TR90 gives the best experience per dollar.
• If you’re building for performance athletes or outdoor pros, nylon is worth every cent.
• If you need fast volume and are price-sensitive, PC gets the job done—but it’s not forgiving.

Manufacturing & Production Comparison

Making a great frame isn’t just about design—it’s about how smoothly and affordably you can bring that design to life.

Here’s how PC, TR90, and Nylon stack up when it comes to manufacturing, mold cost, processing speed, and customization options:

🛠️ Production Comparison Table

🏭 Factory Notes from Eyewearbeyond

• TR90 is the easiest material for mass production and fast launches. Great for testing multiple SKUs or trending shapes.
• PC gives you consistent results, but needs stronger QC for cracking or warping.
• Nylon requires more advanced tooling, more injection experience, and higher upfront cost—but delivers top-tier frame performance.

⚙️ Summary:

Brand Positioning & Retail Strategy Match

Not every brand is playing the same game.

Some focus on volume and price.
Others aim for lifestyle appeal.
And some need technical credibility in pro markets.

The material you choose for your sunglasses should match the brand story you want to tell, and the retail price point you need to hit.

🟩 PC – For Functional, Price-Sensitive SKUs

Best for:

• Mass-market frames
• Entry-level sport collections
• Promotional SKUs or utility glasses

Target customer:

• Bargain hunters
• Distributors supplying schools, events, logistics staff, etc.

Retail price point:
💰 $15–$35 USD

Sales channels:
✅ Bulk wholesale, OEM orders, low-cost eCommerce

🟦 TR90 – For Everyday Sports and DTC Brands

Best for:

• Brands mixing fashion + sport
• DTC players on Amazon, TikTok, or Shopify
• Comfort-focused eyewear lines

Target customer:

• Commuters
• Weekend athletes
• Gen Z / Millennial shoppers who care about feel

Retail price point:
💰 $35–$79 USD

Sales channels:
✅ Online DTC, mid-tier optical chains, outdoor retailers

🟥 Nylon – For Premium, Performance-Driven Collections

Best for:

• Technical brands
• Outdoor gear specialists
• Flagship models or hero SKUs

Target customer:

• Cyclists, runners, tactical users
• Customers who care more about specs than style

Retail price point:
💰 $79–$149+ USD

Sales channels:
✅ Specialty retailers, brand websites, high-end eCommerce

🎯 Strategy Tip:

You can (and should) use different materials for different price tiers:

• Use PC for volume fillers
• Use TR90 for bestsellers
• Use Nylon for flagship launches

This creates a natural “good / better / best” product ladder—and that’s exactly what customers expect when shopping for eyewear today.

Which Material Should You Choose Based on Your Goals?

Let’s make this simple.

No matter what kind of eyewear business you’re running, your ideal material depends on your goals, your customers, and your product positioning.

Here’s a breakdown based on real-world buyer profiles:

👔 You’re a Wholesaler or Bulk Buyer Focused on Price and Volume

Go with: ✅ PC

Why:

• Lowest mold & unit cost
• Fast turnaround
• Easy to manage large PO cycles
• Ideal for utility, promo, or basic SKU sets

📦 You’re a DTC Brand Launching Fast, Light, and Trendy Collections

Go with: ✅ TR90

Why:

• Lightweight + comfy = happy customer reviews
• Mold cost is low enough for frequent new launches
• Ideal for cycling, activewear, or unisex lifestyle lines
• Can handle short runs and fast color changes

🏕️ You’re a Premium Brand Focused on Performance & Durability

Go with: ✅ Nylon

Why:

• Withstands rough use, sweat, sun, cold
• Feels “premium” in hand, fits high-end pricing
• Perfect for mountain, tactical, and pro sport use
• Matches well with prescription lenses in outdoor applications

💡 Mix & Match? Absolutely.

Many successful brands combine all three:

• Use TR90 for volume-driving SKUs
• Use PC for value collections or kids’ lines
• Use Nylon for hero products or limited drops

This gives you more pricing flexibility, market coverage, and room to experiment—without changing your entire production system.

Common Mistakes When Comparing Materials

We’ve worked with hundreds of eyewear buyers—from first-time DTC founders to seasoned wholesalers—and we’ve seen the same mistakes happen again and again.

Here are the most common pitfalls when comparing PC, TR90, and Nylon—and how to avoid them:

❌ Mistake #1: Assuming All Plastics Are Interchangeable

Some clients think:

“Let’s just swap PC for TR90—it’s softer, right?”

Wrong. Each material has unique shrinkage, flow behavior, and mold compatibility. Using the wrong material in the wrong mold = warped frames, poor lens fit, or uneven surfaces.

✅ Fix: Always design your mold for the specific material. Don’t reuse across types unless advised by your manufacturer.

❌ Mistake #2: Choosing Nylon Without Budget for Tooling or Time

Nylon is premium, yes—but it’s not plug-and-play. It needs:

• Higher mold precision
• Slower injection cycles
• More time for prototyping

We’ve had clients insist on nylon, then panic at the lead time or cost.

✅ Fix: Choose nylon only if your price point, customer, and brand positioning justify it. Otherwise, start with TR90 and upgrade later.

❌ Mistake #3: Using PC or TR90 for Pro-Level Sport Frames

Trying to build a high-performance cycling or tactical frame using PC or TR90 is a recipe for disappointment.

They may feel fine at first—but over time, under UV/sweat/heat pressure, they lose form or break.

✅ Fix: For real outdoor athletes or professionals, Nylon is the only material that survives long-term abuse.

❌ Mistake #4: Focusing Only on Price, Ignoring Fit & Feel

It’s easy to get obsessed with material cost per unit—but if the frame feels cheap, your customers will notice.

Returns, bad reviews, and lower repeat sales cost more in the long run.

✅ Fix: If you’re building a brand (not just selling stock), choose a material that aligns with your brand experience—even if it costs a little more.

❌ Mistake #5: Picking Materials Without Thinking About Color Finish

Each material handles color differently:

• PC: can be painted or sprayed
• TR90: doesn’t hold paint, color must be injected
• Nylon: limited to pigment-based injection, fewer color choices

✅ Fix: Plan your color strategy based on material limitations—don’t design the color first, then realize the material can’t handle it.

Conclusion: Make the Right Choice Based on Real Needs

There’s no one-size-fits-all when it comes to frame materials.

• PC is solid and affordable—great for basic functionality and high-volume orders
• TR90 offers comfort, speed, and flexibility—perfect for brands that move fast
• Nylon is premium, durable, and professional—ideal for high-performance or flagship models

The smartest eyewear brands aren’t just picking what’s cheapest—they’re picking what fits their market, customer, and business goals.

At Eyewearbeyond, we’ve helped hundreds of clients around the world:

• Choose the right material for their price point
• Avoid common manufacturing traps
• Develop high-quality frames using PC, TR90, or Nylon—based on what works, not just what’s trending

👓 Need Help Deciding?

Whether you’re planning your next line or testing a new concept, we’re here to help.

Tell us what kind of frame you’re building—and we’ll help you choose the best material to match.

Let’s make sports sunglasses that sell, last, and feel great to wear.