A system for adjusting a gap in a slot die for producing a polymeric web. The system includes a slot die that has a polymer reservoir that extends between a polymer inlet and a melt outlet. The melt outlet has a first edge and a second edge that each extend longitudinally along the melt outlet. The second edge is opposite the first edge. A plurality of actuators move the second edge along a plurality of positions along a length of the second edge. The first edge is spaced apart from the second edge by a gap that has an adjustable profile. A pressure sensor communicates with the reservoir and measures the pressure of the polymer in the reservoir. A control unit with an algorithm correlates the profile of the gap to the pressure in the reservoir. The algorithm is configured to generate control signals to cause the profile of the gap to be uniform.

A method to control die bolts of a flat extrusion die that calibrates a zero-line calibration thickness profile, measures a variation in thickness of a film/sheet 214 by temperature change of at least one lip adjustment bolt 206a, ..., 206n by a processor 122 and records a corresponding die bolt influence area. It further calculates a voltage correction factor of the at least one lip adjustment bolt 206a, ..., 206n based on the die bolt influence area using the measured variation in thickness at the at least one lip adjustment bolt position 206ap, ..., 206np and a variation in thickness at a mean lip adjustment bolt position 206ap, ..., 206np and actuates the at least one lip adjustment bolt 206a, ..., 206n by applying the voltage correction factor and correcting the variation in thickness of the film/sheet 214 to the zero-line calibration thickness.

A die has an inner die that has a straight portion of circular columnar outer shape and a convergent tapered portion provided closer to an extrusion port side than the straight portion and an outer die that houses the inner die. A first supply passage connecting a first valve and a flow passage, a second supply passage connecting a second valve and the flow passage, and a third supply passage connecting a third valve and the flow passage are provided inside the die. Downstream side end portions of the first supply passage and the second supply passage are connected to a portion of the flow passage formed between the straight portion and the outer die and a downstream side end portion of the third supply passage is connected to a portion of the flow passage formed between the tapered portion and the outer die.

There is described a method and system for regulating an extrusion process by obtaining a first thickness at a first position along an extrudate as material is extruded through a die gap of a die; comparing the first thickness with an expected thickness of the extrudate at the first position to obtain a value for an error, the expected thickness modeled in real-time using a size of the die gap as input; and varying the size of the die gap when the error exceeds a threshold to compensate for the error. There is also described a method and system for determining an expected thickness of a material during an extrusion process.

A system for making a nonwoven nonwoven spun-bond or melt-blown fabric has a spinneret for spinning fibers or filaments, a cooler downstream of the spinneret for cooling the spun fibers or filaments, a stretcher downstream of the cooler for stretching the cooled fibers or filaments, and a conveyor downstream of the stretcher. The stretched and cooled fibers or filaments are deposited as a nonwoven web on the conveyor. Sensors measure input parameters at the spinneret, at the cooler, at the stretcher, and/or at at least one diffuser or at the conveyor. An evaluating unit for determining an output parameter from the measured input parameter with respect to a predetermined reference parameter.

A resin foam production apparatus is provided including: a metal mold including a foaming part and a discharge part; and an extruder configured to feed a resin foamable composition into the metal mold to cause the resin foamable composition to pass through the discharge part. The resin foamable composition comprises at least one type of resin. A ratio of resin pressure Cp2 at the foaming part of the metal mold relative to resin pressure Cp1 generated by the extruder is 0.3 or more.

Various embodiments related to three dimensional printers, and reinforced filaments, and their methods of use are described. In one embodiment, a void free reinforced filament is fed into an extrusion nozzle. The reinforced filament includes a core, which may be continuous or semi-continuous, and a matrix material surrounding the core. The reinforced filament is heated to a temperature greater than a melting temperature of the matrix material and less than a melting temperature of the core prior to extruding the filament from the extrusion nozzle.

An additive manufacturing system configured to a 3D print using a metal wire material includes a drive mechanism configured to feed the metal feedstock into an inlet tube and a liquefier. The liquefier has a chamber configured to accept the metal feedstock from the inlet tube. The metal feed stock is heated in the chamber such that a melt pool is formed in the chamber. The liquefier has an extrusion tube in fluid communication with the chamber, the extrusion tube having a length (L) and a diameter (D) wherein the ratio of length to diameter (L/D) ranges from about 4:1 to about 20:1. The system has a platen with a surface configured to accept melted material from the liquefier, wherein the platen and the liquefier move in at least three dimensions relative to each other. The system includes a regulated source of pressurized inert gas flowably coupled to the liquefier and configured to place a controlled positive pressure onto the melt pool sufficient to overcome the resistance of the extrusion tube such that a part may be formed by the extrusion of the liquidus metal along toolpaths defined by the relative motion of the liquefier and the platen.

A method enabling the selection, modification and/or creation of polymer materials which can provide improved response to the application of local shear and/or extensional deformation inside the polymer melt in manufacturing technologies including injection molding, injection stretch blow molding, direct injection, extrusion blow molding, sheet extrusion, thermoforming, etc., is provided. A method for manufacturing a polymer article includes injecting or extruding molten polypropylene, polyethylene or polyester based polymer for converting it into semi-final shape while applying shear and/or extensional deformation on the polymer melt. Applying shear and/or extensional deformation on the polymer melt includes selectively modifying the flow path of the molten semi-crystallizable polymer as a function of local pressure profile over at least part of the flow path. Local pressure profile is a function of optimized response of the polymer melt to the applied local shear and/or extensional deformation over at least the part of the flow path.

A film forming apparatus includes a die device which extrudes a molten resin in a tube shape to form a film and a controller which controls the die device. The die device includes an inner peripheral member which defines an inner periphery of an annular discharge port, an outer peripheral member which surrounds the inner peripheral member and defines an outer periphery of the discharge port, and an adjustment portion which applies a load to at least one of the inner peripheral member and the outer peripheral member to elastically deform the at least one of the inner peripheral member and the outer peripheral member and change a radial width of the discharge port. The controller controls a thickness of the film with the load applied by the adjustment portion.