Advanced Slot Die Design
Using Computational Fluid Analysis
New Service!
Common Concerns
- We want to verify in advance which coating conditions are suitable for our applications — but we don't know how.
- We want to modify the shape of the slot die — but we’re not sure which design is best.
- We need a slot die that can achieve our targeted coating results — but we don’t know what needs to be adjusted.
- We want to evaluate our coating conditions theoretically.
- We need a slot die optimized for our specific materials.
- We want to scale up to a wider coating width.
Our Solutions Consist of Four Critical Steps:
From analysis to final production, each phase is handled with the expertise and precision that only Yasui Seiki can deliver.
1. Computational Fluid Analysis
Using Cham’s PHOENICS, a well-established and widely adopted Computational Fluid Dynamics (CFD) program in our industry, we begin by visualizing and analyzing the fluid dynamics—such as flow rate, pressure, and velocity—within a 3D model of the slot die.
What sets our analysis apart is the integration of decades of hands-on expertise from the Yasui Seiki Group in the roll-to-roll coating industry. We gather key input from our customers and adjust the simulation results to reflect what is realistically achievable in practical coating environments.
From this advanced fluid analysis, we can estimate the potential coating thickness, which enables us to evaluate the impact of various slot die shape modifications and optimize the design accordingly.
2. Coating Simulation Using Yasui Seiki’s Proprietary Software
Using our proprietary simulation tool—developed based on theoretical formulas—we can perform a wide range of coating simulations. This tool enables us to calculate and graph various parameter values.
Simulations are conducted using key parameters for slot die coating, including fluid properties, coating conditions, and slot die structure.
In addition, we evaluate the simulation results using our extensive in-house knowledge and experience. This combined approach allows us to determine coating feasibility and identify the most optimal coating conditions.
3. Custom Slot Die Design Informed by Simulation Results
Based on the theoretically optimal shape derived from the fluid analysis and coating simulation, we collaborate with the customer to evaluate its practicality and finalize a detailed structural design for the slot die.
We then perform a second round of fluid analysis on the proposed slot die design. At the same time, we incorporate necessary design modifications by considering the structure of the customer’s target equipment and implementing any additional customer requests. This integrated approach enables us to deliver a truly original, custom slot die nozzle tailored to the customer’s specific needs.
4. Precision Manufacturing of the Custom Slot Die
Using the finalized design from Step 3, Yasui Seiki will manufacture a high-precision custom slot die nozzle in-house.
Material changes and other specific requirements can also be accommodated. If the structure is compatible with our in-house demo equipment, we can conduct demo tests at our facility to verify performance before delivery.
Even the material is Yasui Seiki original — with custom stainless steel and duralumin available (patent pending)!