How does a desktop small precision extrusion casting machine achieve full-process functional integration in a compact design?

Publish Time: 2025-10-20

In the field of polymer materials research and development, cast film technology is a core process for producing key functional materials such as films and sheets. Traditional cast film production lines are bulky, energy-intensive, and require long commissioning cycles, making them difficult to meet the needs of laboratory R&D requiring small batches, multiple formulations, and rapid iteration. To address this pain point, the desktop small precision extrusion casting machine was developed. This machine integrates a precision single-screw extruder, a casting die, a cooling system, a traction device, a trimming mechanism, and a winding unit into a single, highly integrated desktop device, automating the entire process from raw material plasticization to finished product winding. Its core challenge and innovation lies in achieving efficient coordination and precise control of a complex process chain within a limited space.

1. Modular Design and Optimal Space Layout

The primary strategy for achieving full-process integration is modularization and compact design. The entire machine utilizes a combination of vertical tiering and horizontal tandem layout: the extruder is located at the rear or bottom of the machine, conveying the melt to the cast film die at the front via precisely aligned connecting flanges. Below the die, a height-adjustable chill roll assembly rapidly cools the film. After cooling, the film is stably conveyed by upper and lower take-up rollers to the trimming unit. The trimmed finished product is then guided by guide rollers to the front-end winding system for rewinding. Each functional module is meticulously designed using precise calculations and 3D simulations to minimize material transfer paths and avoid wasted space, while also ensuring accurate alignment and operational stability between units.

2. High-Precision Drive and Synchronous Control System

Advanced drive and synchronous control technology is essential for achieving coordinated operation of multiple stations within a confined space. The machine utilizes servo motors to drive the extrusion screw, take-up rollers, and winding shaft, with multi-axis linkage control implemented via a PLC or industrial control system. A closed-loop feedback mechanism between extrusion speed, take-up rate, and winding tension ensures uniform film thickness, wrinkle-free operation, and zero breakage during stretching. The control system allows preset process parameters and one-click start of the entire line, significantly reducing operational complexity and improving experimental repeatability.

3. Integrated Casting Auxiliary Equipment and Thermal Management Design

Temperature control during the casting process directly impacts the film's crystallinity and surface quality. Despite the limited space available in this benchtop device, a precise temperature control system is integrated: the extruder is equipped with zoned heating and cooling to ensure uniform plasticization of the material; the die head utilizes electric heating and a hot runner design for highly precise control of the lip temperature; and the cooling roll features built-in circulating coolant channels that, in conjunction with an external refrigeration unit, rapidly remove heat, achieving isothermal or gradient cooling. All temperature control modules are centrally located within the device, separated by high-efficiency thermal insulation to prevent thermal interference and ensure system stability.

4. Miniaturized Functional Units and Optimized Ergonomics

To accommodate the benchtop form factor, key components within the device have been miniaturized and enhanced. For example, the pull-off roller assembly utilizes high-precision bearings and a lightweight roller body, ensuring rigidity while minimizing size. The trimming device uses high-speed rotating blades or laser cutting technology to precisely remove scrap material, which is then collected centrally by a negative pressure system. The winding system supports either air shafts or mechanical clamping to accommodate various roll diameters. The entire machine housing features a removable design for easy maintenance and cleaning, and the user interface is simple and intuitive, meeting laboratory ergonomic requirements.

The desktop small precision extrusion casting machine utilizes modular integration, precise drive control, efficient thermal management, and miniaturized design to successfully implement the complete casting process chain, from plasticizing and extrusion to finished product winding, within the confines of a limited benchtop space. This not only significantly reduces the equipment threshold and space requirements for polymer material R&D, but also, with its ease of operation, rapid response, and data traceability, it is an ideal tool for new material development, formulation optimization, and process validation.