Cast Films and Membranes

Carestream Contract Manufacturing’s precision coating and prototyping services enable cost-effective, large volume film casting. We enable many demanding custom cast films and membranes for a variety of applications including battery, fuel cell and beyond.

Our coating assets feature the longest and most precision-controlled ovens in North America (up to 2,000 ft) to coat extremely uniform films at high line speeds. We create stand-alone “free films” by casting aqueous dispersions, polymers dissolved in organic solvents or 100% solids formulations. These solutions may be cast onto a release liner with specific properties to manage film quality and specific release requirements or adhered to a desired substrate.

Common Process / Product Requirements:

  • On-site mixing of the formulation(s)
  • Low to high viscosity and filled or unfilled formulations
  • Slot die and curtain coating
  • Thermal or UV curing
  • Thickness uniformity of ± 1% to 5%
  • Pinhole free
  • Controlled release of the free film after casting
  • Multi-layer – addition of another layer in-line
  • Lamination
  • 100% automated optical inspection

Custom Cast Film and Membrane Examples:

Trust Carestream to help bring your cast film or membrane products to commercial scale-up and manufacturing quantities. Contact Robert Wildman to learn more about our in-depth coating and contract manufacturing knowledge.

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