Are you NEW to Precision Slot Die Coating Technology?
What is Slot Die Coating Technology and How do Slot Dies Work?
Introduction
Slot die technology is at the forefront of precision coating solutions, enabling manufacturers across industries to achieve unparalleled accuracy, efficiency, and material savings. Whether you're new to this innovative technology or looking to optimize your current processes, understanding the basics of slot dies is the first step toward unlocking their potential.
​
Custom slot die solutions are utilized in industries including, but not limited to renewable energy, solar, and lithium-ion batteries to packaging, medical and pharmaceutical applications and everything between.
What is Slot Die Technology?
Slot die technology is a precision coating method used to apply a uniform layer of material onto a substrate or web. This method is highly versatile, accommodating a variety of materials, viscosities, and substrates, including plastics, paper, and metal foils.
Unlike traditional coating methods, slot dies deliver:
-
Superior Uniformity: Achieve coating thicknesses as thin as a micron to millimeters with minimal variation.
-
Reduced Waste: Minimize material usage with precise deposition, lowering costs.
-
Repeatability: Consistent process for precision coating results.
-
Scalability: Adaptable for lab-scale testing and full production runs.
SUBSTRATE
SLOT DIE
FLUID COATING
How Slot Dies Work
Slot dies, also known as flat die heads, use a controlled flow of liquid material dispensed through a precision-engineered die lip. This controlled fluid flow is typically distributed using a fluid delivery system onto a substrate. The substrate moves beneath the die at a consistent speed, ensuring even application.
​
Critical factors include:
-
Die Lip Design: Controls coating thickness.
-
Fluid Delivery System: Regulates material flow.
-
Process Speed: Synchronizes with substrate movement for uniform coverage.
-
Shim Thickness: OFFSET shims control lip adjustments while BODY shims control coating thickness.
​
Slot dies can be mounted in any orientation as a part of a coating line or can be integrated into an existing coating line with the use of a slot die coater machine.
Basic Parts of a Slot Die - External Part 1
A slot coating die consists of several key components essential for its function. The main parts include:
​
-
the DIE BODY which houses the internal flow path for the coating material. All dies have an UPPER DIE BODY and a LOWER DIE BODY.
-
Multilayer slot dies can have up to 2 middle sections called a WEDGE or UPPER/LOWER WEDGE. A wedge allows for additional coating capabilities.
-
A DUAL LAYER SLOT DIE has 1 middle wedge​
-
A TRIPLE LAYER SLOT DIE has an UPPER wedge and a LOWER Wedge.
-
Due to size constraints, a triple layer slot coating die is the maximum layer capacity PER slot die.
-
-
-
-
the LIP, where the coating exits the die and meets the substrate.
-
and the SLOT or SLOT/LIP GAP, which determines the thickness of the coating is located between the UPPER and LOWER BODY LIPS
Additionally, there are adjustment mechanisms for fine-tuning the flow and alignment, as well as mounting brackets for secure installation. Understanding these is crucial for optimizing the coating process in various industrial applications.
SLOT/LIP GAP
UPPER DIE BODY
LOWER DIE BODY
UPPER DIE BODY
LOWER DIE BODY
LIP
Basic Parts of a Slot Die - Internal
The internal parts of a slot die play a crucial role in the precision and efficiency of slot die coating technology.
Key components are:
​
-
the MANIFOLD coating chamber a
-
the Lip LAND design ensure even distribution and control of the coating material, leading to high finishes.
-
In the slot die coating industry, the design of the manifold and land is crucial for achieving uniform coating thickness and optimal flow characteristics.
-
Manufacturers providing custom manifold designs allow for tailored solutions that meet specific application requirements, enhancing efficiency and performance. ​
-
In contrast, manufacturers who provide cookie cutter manifold designs may not address unique needs, leading to inconsistent results. Choosing a manufacturer that specializes in custom designs ensures that you receive coating tooling that maximizes your coating process and minimizes waste.
-
-
the THROAT and
-
the INLET design affect fluid flow rate for consistent coating thickness. ​
​
Understanding these parts are essential, as they influence factors like flow rate and coating thickness, ultimately affecting product performance. By optimizing the design and function of these internals, manufacturers can achieve superior coating results for various applications.​
Basic Parts of a Slot Die - External Part 2
A slot coating die consists of several key components essential for its function. The main parts include:
​
-
the DIE BODY which houses the internal flow path for the coating material. All dies have an UPPER DIE BODY and a LOWER DIE BODY.
-
Multilayer slot dies can have up to 2 middle sections called a WEDGE or UPPER/LOWER WEDGE. A wedge allows for additional coating capabilities.
-
A DUAL LAYER SLOT DIE has 1 middle wedge​
-
A TRIPLE LAYER SLOT DIE has an UPPER wedge and a LOWER Wedge.
-
Due to size constraints, a triple layer slot coating die is the maximum layer capacity PER slot die.
-
-
-
-
the LIP, where the coating exits the die and meets the substrate.
-
and the SLOT or SLOT/LIP GAP, which determines the thickness of the coating is located between the UPPER and LOWER BODY LIPS
Additionally, there are adjustment mechanisms for fine-tuning the flow and alignment, as well as mounting brackets for secure installation. Understanding these is crucial for optimizing the coating process in various industrial applications.
Applications of Slot Die Technology
Slot die technology is used across diverse industries for applications such as:
-
Lithium-Ion Batteries: Electrode and separator coatings.
-
Electrode Coating: Ensures uniform deposition of active materials for improved battery efficiency.
-
Separator Films: Achieves consistent insulation to enhance safety and performance.
-
-
Renewable Energy: Thin-film photovoltaic applications.
-
Photovoltaics: Uniform thin-film coatings increase light absorption and energy efficiency.
-
Fuel Cells: Precise application of catalysts for optimal chemical reactions.
-
-
Pharmaceuticals: Coating for transdermal patches and medical devices.
-
Transdermal Patches: Delivers consistent drug dosages through precise coating.
-
Diagnostic Strips: Uniform reagent coatings ensure accurate test results.
-
-
Electronics: Display and circuit manufacturing.
-
Flexible Displays: Ensures defect-free coatings for next-generation screens.
-
Printed Circuit Boards: Applies even coatings of solder mask or conductive inks.
-
-
Packaging: Adhesive, Barrier, Laminate, and Decorative coatings.
-
Food and Beverage Coatings: ​Precise application in multilayer constructions for adhesion and laminates to prevent moisture, condensation, oxygen, grease, and oil, enable tamper-proof sealing, and apply eco-friendly coatings.
-
Decorative Coatings: Enhance visual appeal and durability with gloss or matte finishes or holographic coatings.
-
​
You can find slot die coating technology in many other industries such as automotive, aerospace, marine, construction, architectural, electronics, touch screens, tapes and labels, solar, textiles, food, medical device, and much more!
Why Choose Precision Die Systems?
With years of experience in precision coating, our team provides:
-
Custom Solutions: Every slot die is engineered to your exact application.
-
Proven Expertise: Trusted by top manufacturers across industries.
-
Ongoing Support: From design to installation and beyond.
-
Performance Standards:
-
Flatness/Straightness Deviation: Guaranteed 0.0001" or 2.54 microns, over full length and width. "Better upon request" sub-micron finish also available as application requires.
-
Lip Face and Flat Flow surface Deviation" Precision micro-ground and diamond lapped: 1-3Ra
-
Flatness Inspection Reporting
-
-
Proof of Process: Wet lab and Lease Die Equipment
Why Choose Our Slot Die Systems?
With years of experience in precision coating, our team provides:
-
Unparalleled Precision: Advanced engineering ensures maximum accuracy and repeatability for uniform coatings.
-
Durable and Versatile Construction: High-quality materials and optional customizations meet the demands of various industries.
-
Comprehensive Support: Included manuals, tool kits, and shipping containers simplify integration and maintenance.
​
Interested in learning how these features can improve your coating process? Contact us today to speak with an expert and request a personalized quote. Let us help you optimize your slot die system!
Ready to Take the Next Step?
If you're exploring slot die technology or looking for a reliable partner, Precision Die Systems is here to help. Our experts are ready to discuss your unique needs and recommend a solution tailored to your application.
​
Fill out our contact form today to learn more about how slot die technology can enhance your production process.
Learn More about
Precision Slot Die Types
Slide Curtain Dies
Cascade Dies
Triple Layer Fixed Slot Die
Ancillary Equipment for Coating Dies
Contact Us to Learn More
Whether you’re exploring slot die technology for the first time or seeking a partner to optimize your production, Precision Die Systems is ready to help.
Fill out our contact form to speak with one of our experts and find the perfect solution for your needs.
