Slot-die coating for carbon capture & DAC
Why slot-die coating matters for carbon capture and DAC
Carbon capture from point sources and ambient air (DAC) depends on thin functional films—amine sorbents, polymer membranes, and solid-sorbent composites. Film uniformity, thickness, and porosity drive flux, selectivity, and capacity; adhesion and durability set lifetime. Slot-die coating provides pre-metered deposition with controlled drying, slot-die coating lets you scale width and throughput and allows for transfer the same recipe to R2R if desired.
At a glance
- Applies to: sorbent laminates, polymer membranes, metal-organic framework (MOF) based composites.
- What matters: uniform films (~100 nm to tens of µm), tuned porosity, strong adhesion, defect-free coatings.
- Why slot-die: pre-metered, low-waste coating with clean, enclosed flow paths.
- Drying control: multiple drying options such as IR or hot-air helps set structure and prevent defects.
- Repeatability: recipe-controlled parameters for easy reproducibility.
- Scaling path example: start on sheet coater or smaller R2R option and move to pilot-scale R2R later without changing recipe logic.
Typical coating challenges
- Scaling lab inks to large-area films
Uniform coat weight and porosity across pilot widths determine capture efficiency, pressure drop, and reproducibility. - Variable rheology
High-solids sorbent slurries can bead at edges or stripe unevenly, creating defects and wasted material. - Drying/porosity tuning
Pore structure sets capacity and kinetics; poor drying causes cracking, pore collapse, or deactivated surfaces. - Coating peeling on flexible surfaces
Layers detach in heat or humidity, causing early failure and poor performance. - Moisture-sensitive chemistries
Some amines/MOFs require controlled humidity/temperature to avoid degradation and safety risks. - Membrane coating control (nm-scale)
Flux/selectivity depend on a thin, pinhole-free selective layer uniformly covering porous supports.
What layers to coat with slot-die
Solid sorbent sheet for DAC
- Breathable overcoat / barrier
- Porosity/transport modifier
- Amine sorbent layer
- Adhesion / primer
- Porous substrate
CO₂-selective polymer membrane
- Protective topcoat
- Dense selective skin
- Porous support
MOF-based capture film
- Protective overcoat
- MOF composite selective layer
- Gutter/interlayer
- Porous support
Structured filters/contactors with sorbent coating
- Post-treatment / overcoat
- Sorbent precursor coating
- Mesh/foam substrate
Advantages of slot-die coating in carbon capture & DAC
Here’s what slot-die adds to your lab and pilot workflows.
- Uniform thickness across the entire width: consistent coating weight from edge to edge, even at larger pilot scales.
- Smooth, clean edges with thick inks: maintains a stable process that prevents messy edges or “beading,” even with heavy slurries.
- Controlled drying to prevent cracks: customizable heating zones that set the right porosity and stop the surface from cracking.
- Stronger bonding on flexible materials: precise control over layers to ensure coatings stick properly and don’t peel off.
- A protected environment for sensitive materials: an enclosed system that manages humidity and temperature to keep delicate chemistries safe.
- Ultra-thin, flawless layers: extremely precise control to create perfect, paper-thin membranes without any holes.
Case spotlight: Scaling CO₂ electrolysis for next-gen carbon transformation
The captured CO2 from DAC activities can be directly utilized and transformed to valuable products when combined with CO2 electrolysis or similar.
The challenge: A pioneer in carbon transformation technology is working to redefine emissions by converting CO₂ into essential industrial products and sustainable fuels. Their process relies on specialized Membrane Electrode Assemblies (MEAs) designed for CO₂ reduction. Scaling these from small lab samples to pilot-ready sizes (approx. 300 x 300 mm) presented a significant hurdle: coating low-viscosity carbon slurries onto sensitive polymer membranes. Traditional methods struggled to achieve uniformity over large areas, and the high cost of the catalyst inks meant that material waste from overspray or edge effects was not an option.
The approach: To bridge the gap between lab-scale to pilot-scale, the company deployed a high-precision FOM slot-die sheet coating solution. The system was selected for its ability to handle large-area substrates with a heated vacuum chuck, which proved critical for maintaining membrane flatness and controlling drying kinetics.
- Precision control: The slot-die head ensured a closed, pre-metered flow, minimizing the waste of expensive catalyst slurries while preventing premature drying within the head.
- Process window: The team utilized the heated chuck and optimized coating speeds to lock in a stable process window, ensuring the low-viscosity ink dried uniformly without disrupting the underlying membrane.
The outcome: The transition to FOM’s slot-die platform provided the capability to coat large-area MEAs while addressing the critical issue of material waste. This transition equipped the R&D team with a scalable, standardized method to test and refine their catalyst layers, establishing a technical pathway from lab-scale research toward their broader goals for industrial-scale CO₂ transformation.
How FOM Technologies can help your research
Our lab scale machines
Built for fast-paced research, our lab tools create perfectly even layers with very little material waste. They are easy to set up and adjust, making them perfect for testing new materials quickly without wasting expensive inks.
These machines fit easily into gloveboxes or cleanrooms and save your protocols to ensure the same results every time, or do structured testing of different parameters. Because the process is so precise, the “recipe” you perfect in the lab is immediately ready to be scaled up for larger pre-pilot and pilot scale.
Our pre-pilot and pilot scale
Step up to wider widths and faster speeds without the typical scaling risks. By using the same slot-die heads and software as our lab tools, these platforms ensure a seamless transition from the bench to the pilot line. This continuity allows you to lock in your settings and build confidence as you scale your research from small samples to larger rolls.
Pilot scale
The FOM moduloR2R offers reliable roll-to-roll coating with precise control and customizable drying for perfect, defect-free results. You can increase your width and speed without changing your original settings. This allows you to move smoothly from testing your process to producing larger batches with total confidence.
Why it matters
- Save time with easy setup and reusable recipes.
- Get the same results every time with locked settings and history tracking.
- Scale with ease by using familiar software and protocols as you move from the lab to the pilot line.
Expert-led training and research
At FOM Technologies, we are more than just an equipment provider—we are a team of scientists dedicated to your success. We host the largest team of experts in our industry to act as your true knowledge partner, helping you bridge the gap between lab-scale discoveries and pilot-scale success.
Our training and research services provide you with direct access to our leading scientists. Whether you are a new user or a veteran researcher, you will work side-by-side with our application experts to sharpen your skills, solve technical hurdles, and master the art of slot-die coating.
How our experts support your research
- Work directly with our scientists: Collaborate with our expert team to design a custom research plan that addresses your unique material challenges.
- Live, expert-led training: Every training session is a private, live-guided experience led by a FOM scientist, whether it happens online or onsite at your facility.
- Professional research services: Our scientists can execute research at the FOM laboratory on your behalf, providing you with professionally coated samples and optimized process data.
- 1-on-1 expert consultation: Use our “Book a scientist” service for direct, hourly access to our team to troubleshoot specific issues or improve your material performance.
- Hands-on technology demos: Experience a live coating process at our laboratory, guided by our experts to help you understand the full potential of slot-die technology.
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