Custom slot die coating system designed to deliver precision coating control, vibration-free operation, and flexible material handling for advanced laboratory process development
A client required a custom precision coating system to support laboratory-scale developmental work involving a wide range of coating materials and process conditions. The system needed to integrate a slot die provided by a third party while delivering highly accurate coating performance across a stationary substrate measuring 16 inches wide by 32 inches long.
The application introduced several complex engineering challenges. The coating die required extremely smooth and vibration-free translation across the substrate while maintaining a highly controlled coating gap ranging from 0.002 to 0.030 inches. In addition, the system needed to support variable coating speeds between 0.5 and 10 inches per second while preserving dimensional accuracy and coating consistency.
The client also required an integrated drying solution capable of curing coatings prior to substrate removal, along with a highly flexible fluid delivery system capable of handling solid particle dispersions and coating solutions with viscosities ranging from 5 to 200 centipoise. Maintaining stable and repeatable flow rates between 1 and 200 ml/min was critical to ensuring coating uniformity and repeatable laboratory results.
To meet these demanding performance requirements, the client partnered with Re:Build Optimation to design and build a fully customized laboratory coating platform optimized for precision, flexibility, and long-term reliability.
Re:Build Optimation began the project with a detailed evaluation of the client’s coating process requirements, substrate dimensions, fluid properties, and operational goals. The engineering team worked closely with the client to define performance criteria for die positioning accuracy, coating speed control, drying capability, and fluid delivery precision.
Because coating quality depended heavily on minimizing vibration and maintaining tight dimensional tolerances, structural rigidity and motion system performance became primary design priorities. The team evaluated multiple mechanical configurations and motion control strategies to identify a solution capable of delivering smooth and repeatable die translation while maintaining precise coating gap control.
In parallel, Re:Build Optimation developed a thermal drying strategy capable of accommodating varying coating chemistries and drying profiles. Fluid handling requirements were also carefully analyzed to ensure compatibility with a broad range of viscosities and solvent-based materials while maintaining safe laboratory operation.
The resulting design combined precision mechanical engineering, advanced servo motion control, integrated thermal processing, and flexible fluid management into a compact and highly adaptable laboratory coating system.
Re:Build Optimation designed and built a fully integrated precision coating platform tailored to the client’s laboratory development requirements.
Key upgrades included:
To ensure long-term stability and repeatable coating performance, the support framework was fabricated using large structural steel tubing weldments specifically designed to minimize vibration and maintain dimensional alignment over extended operation.
Re:Build Optimation successfully completed the custom coating system within a 30-week timeline, delivering a highly flexible laboratory platform capable of supporting advanced coating process development.
The completed system provided the client with precise control over coating thickness, material flow, translation speed, and drying conditions, allowing researchers to evaluate a wide range of coating formulations and process parameters with exceptional repeatability.
The vibration-resistant structural design and electronically synchronized servo controls enabled smooth and accurate die movement, improving coating consistency and process reliability. Integrated drying and dual-fluid delivery capabilities expanded the system’s flexibility, allowing the client to support evolving laboratory applications and future developmental work.
The coating platform included:
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