Cast Films and Membranes

Creating Custom Cast Films and Membranes

Carestream’s precision coating and prototyping services enable cost-effective, large volume casting of polymer membranes and films. Our coating assets feature the longest precision-controlled ovens in North America (up to 2,000 ft.), backed by stringent clean room, quality inspection and analytical testing practices. We produce extremely uniform custom cast films and membranes at high line speeds including silicone films, optically clear adhesives and thin polycarbonate films.

Our engineers apply their process knowledge, expertise handling multiple solvents, and established relationships with substrate and chemical suppliers to guide customers throughout the casting process. 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.

Casting Capabilities:

  • Precision thickness uniformity as tight as ± 1%
  • On-site mixing of the formulation(s)
  • Ability to handle chlorinated solvents
  • Slot die and curtain coating
  • Long zone-controlled dryers
  • Clean room coating and drying
  • Optional UV curing
  • Multi-layer coating – additional layer(s) in-line
  • Lamination of protective overlays
  • 100% automated optical inspection

Process Development Advantages:

  • Lab, pilot and production coaters available to scale-up solution-cast products
  • Relationships with substrate/chemical suppliers

Custom Cast Membrane and Film Expertise:

Carestream Solution Casting Resources:

Carestream Membrane Datasheet:









For more information, contact Robert Wildman to learn how Carestream can help develop your cast film or membrane products through commercial scale-up.


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