Multilayer materials offer benefits in terms of new materials for packaging and barrier applications. The ability to maintain layer stability as the material flows into different die designs is important for fabrication of these materials. This work investigated different die designs for use in fabricating multilayer films. Three dimensional analyses of different types of manifold designs have been applied to optimize the die design of a coat hanger die. For the horizontal multilayer systems, an elongated tear drop manifold design with a relatively sharp angle provided the most uniform flow and layer distribution. With the vertical multilayer system, however, a gradual change in the manifold geometry enabled more uniform flow. The vertical layered systems also consistently exhibited curving of the layer interfaces. The horizontal layers were not affected by the presence of a secondary manifold, but in vertical layered systems, the secondary manifold produced non-uniformities in the layers and instabilities in the flow.
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