What’s the difference between fixed lip, shimmed lip, and adjustable lip dies?Fixed lips are static and ideal for repeatable processes. Shimmed lips allow fine gap adjustments via spacers. Adjustable lips offer dynamic control during operation, ideal for R&D and variable specs.

Precision Die Systems supplies industrial extrusion coating equipment to manufacturers throughout Wisconsin and the Midwest. We provide custom slot dies, coating heads, pilot‑scale systems, and supporting components designed for precision, repeatability, and long‑term reliability. Our equipment is used in industries such as packaging, battery manufacturing, medical films, adhesives, and advanced materials. Because we design and build our equipment in Chippewa Falls, customers in Wisconsin benefit from local support, faster turnaround times, and direct access to engineering expertise. We also collaborate with OEMs and integrators to ensure your extrusion line is configured for optimal performance. If you’re looking for extrusion coating equipment, pilot systems, or custom die solutions in Wisconsin, our team can help you evaluate your process needs and recommend the right configuration.

Multilayer coating technology improves extrusion processes by allowing manufacturers to apply multiple functional layers in a single, controlled pass. Instead of running several coating steps separately, multilayer slot dies deliver stacked layers with precise thickness control, uniformity, and repeatability. This reduces waste, shortens production time, and improves product performance. Each layer can serve a different purpose — such as barrier protection, adhesion, optical clarity, or conductivity — and multilayer dies keep these layers separate until the moment of coating. This prevents intermixing and ensures consistent layer structure across the entire web. For extrusion operations, this means better material efficiency, tighter tolerances, and more flexibility in product design. Multilayer coating is especially valuable in battery manufacturing, medical films, packaging, and advanced composites where layer accuracy directly affects product quality. By integrating multilayer technology into an extrusion line, manufacturers gain higher throughput, improved coating accuracy, and the ability to scale new formulations more efficiently.

How do I optimize coating uniformity across the web?Use precision die geometry, balanced fluid flow, and proper substrate tension. Adjustable lips and edge bead control also help maintain uniformity.

What factors affect coating bead stability and edge control?Fluid viscosity, coating speed, lip design, and substrate surface energy all play a role. We tailor die geometry to minimize edge defects and maintain bead shape.

Yes, we can help with fluid rheology and die design matching. We collaborate with you to ensure the die design matches the fluid behavior, guaranteeing optimal coating performance and defect-free films.

Do you offer pilot-scale dies for R&D and process development? Absolutely. Our pilot dies are designed for lab-scale testing with full scalability to production, supporting innovation and process validation.

What support do you offer for die installation and startup?We provide installation guides, remote support, and on-site assistance as needed. Our goal is to ensure smooth integration and fast ramp-up.

How do I know when it’s time to refurbish or replace a die?Signs include inconsistent coating, increased downtime, and visible wear. We offer inspection services and performance audits to help you decide.

What are the most common causes of coating defects and how can they be prevented? Defects often stem from poor fluid distribution, misaligned lips, or contamination. Regular maintenance, proper setup, and matched die design help prevent issues.

How does Precision Die Systems support sustainable manufacturing and material efficiency? Our dies are engineered for minimal waste, precise fluid control, and long service life. We help customers reduce scrap, improve yield, and optimize resource use.

Rheology testing is one of the most effective ways to optimize coating processes because it helps you understand how your fluid behaves under different flow conditions. Slot die coating relies on predictable viscosity, shear response, and flow stability. When these properties are measured accurately, you can set tighter process windows and achieve more consistent results. By analyzing viscosity curves, shear thinning behavior, and temperature sensitivity, you can determine the ideal coating speed, gap, pressure, and die configuration. Rheology testing also helps identify issues such as edge bead, ribbing, air entrainment, and flow instability before they appear on the line. Precision Die Systems provides guidance on interpreting rheology data and applying it to real‑world coating conditions. Whether you’re troubleshooting a defect or scaling a new formulation, rheology insights help you reduce waste, improve uniformity, and increase production efficiency.

Precision Die Systems provides multilayer coating technology solutions directly from our facility in Chippewa Falls, Wisconsin. We design and manufacture multilayer slot dies and coating systems that allow manufacturers to apply multiple functional layers in a single pass with precise thickness control and excellent uniformity. Our multilayer systems are used in advanced applications such as battery electrodes, medical films, adhesives, and specialty coatings. Because we engineer these systems in‑house, customers in Chippewa Falls and the surrounding region benefit from local support, faster lead times, and direct access to our technical team. If you’re looking for multilayer coating equipment or want to evaluate whether multilayer technology is right for your process, our engineering team can help you select the appropriate die configuration and system design.