Cast Films and Membranes

Custom Cast Film and Membrane Partnerships

Carestream’s multilayer coating partnerships and prototyping enable cost-effective, large volume casting of polymer membranes and films. We deliver significant process development advantages by providing our partners with project-ready coating and manufacturing facilities in the United States for the development of a wide variety of precision-coated structures. 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. Partners leverage our aqueous and solvent coating proficiency at bench, pilot and production scale to produce extremely uniform custom cast films and membranes at high line speeds including silicone films, optically clear adhesives and thin polycarbonate films.

Carestream engineers apply their process knowledge, expertise handling multiple solvents and established relationships with substrate and chemical suppliers to guide partners throughout the casting process. Stand-alone “free films” are created 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
  • Multilayer 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:

cast film, membrane casting

Carestream actively seeks growth partnerships, including joint development, manufacturing partnership or full joint venture, which combine customer product IP and market channels with our high-speed roll-to-roll processing, quality systems and worldwide presence. For more information, contact Robert Wildman to learn how to partner with Carestream to develop your cast film or membrane products through commercial scale-up.


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