Custom Die Design for your Coating Application

🧠 Slot Coating Die Design Process: From Fluid to Precision

At Precision Die Systems, every slot coating die is engineered with purpose — tailored to your fluid properties, coating requirements, and production goals. Our design process blends proprietary simulation software, hands-on expertise, and collaborative engineering to deliver dies that perform with exceptional flatness, uniformity, and repeatability.

​

🔍 Step 1: Application Discovery & Requirements Gathering

 

We begin by understanding your coating goals:

• Target coating thickness and width

• Substrate type and line speed

• Fluid rheology (viscosity, surface tension, density)

• Coating environment (temperature, humidity, cleanroom requirements)

• Integration needs (pilot coater, production line, lab-scale setup)

 

Whether you're coating battery films, medical adhesives, or flexible packaging, we tailor every design to your specific use case.

​

🧪 Step 2: Rheology Data Collection & Analysis

 

To design the internal flow geometry, we need accurate fluid behavior:

• You can provide rheology data directly

• Or send fluid samples — we’ll coordinate certified lab testing

• Our software models flow curves (peak, valley, M-curve, W-curve, S-curve) to identify risks and design corrections

 

This step ensures your die will deliver ±1% cross-web uniformity, even with challenging or multi-viscosity fluids.

​

🧰 Step 3: Internal Flow Simulation, Die Body & Internal Geometry Design

 

Using proprietary software, we simulate:

• Manifold geometry for balanced flow distribution

• Lip design (fixed, shimmed, adjustable) for coating bead control

• Body Design (Overall size, internal pressure analysis, hinge and offset block features)

• Channel dimensions to match fluid viscosity and throughput

• Thermal management for temperature-sensitive coatings

 

We iterate designs to eliminate distortion and optimize coating flatness at the die lip exit.

​

📐 Step 4: Precision Machining & Surface Finishing

 

Once the design is validated, we manufacture the die using:

• High-grade stainless steel or corrosion-resistant alloys

• Mirror-polished coating surfaces (Ra < 0.05 µm)

• Tight machining tolerances for repeatable performance

• Optional quick-disassembly features for easy cleaning and changeover

 

Every die is built to withstand demanding production environments and deliver consistent results.

​

📊 Step 5: Validation, Documentation & Delivery

 

Before shipment, we provide:

• Flow distribution graphs (like the one shown above)

• Dimensional drawings and mounting specs

• Cleaning and maintenance guidelines

• Optional startup support or remote consultation

 

We ensure your die arrives ready to perform — whether for R&D, pilot testing, or full-scale production.

​

🔄 Bonus: Multi-Fluid Design Capability

 

Planning to run multiple fluids through one die? We’ve got you covered.

• Simulate multiple rheologies in one design

• Engineer internal geometry for fluid flexibility

• Minimize changeover time and maximize coating consistency

• Ideal for battery, medical, and packaging lines with evolving chemistries

​​

🌍 Built for Innovation, Backed by Experience

 

Precision Die Systems is trusted by manufacturers worldwide for:

• Slot coating dies with unmatched uniformity

• Custom designs for regulated and high-growth industries

• Engineering support that goes beyond the sale

​​

Let’s design a die that works for your process — not just your product.