What Is a Tape Caster?
A Tape Caster is a specialized production system that enables ceramic or similar materials to be cast into a continuous and homogeneous layer at a defined thickness. In this system, a prepared suspension (slurry) is cast in a controlled manner onto a carrier belt or surface and spread to the desired thickness using an adjustable blade (doctor blade).

Thanks to the tape casting method:

• Thin and homogeneous layers are obtained

• Thickness can be precisely controlled

• Continuous and repeatable production is achieved

• Surface quality and material distribution are optimized

These features make Tape Caster systems indispensable, especially for advanced technology applications.

DMR Tekno’s Tape Caster Approach
DMR Tekno adopts a process-oriented and application-specific engineering approach in Tape Caster projects. Each material has different viscosity, particle size, binder structure, and drying behavior. Therefore, instead of a standard Tape Caster solution, systems are designed entirely specific to the application.

DMR Tekno’s Tape Caster approach is based on the following core principles:

• High thickness precision

• Stable and vibration-free mechanical structure

• Advanced automation and control

• Ease of use and maintenance

• Long-lasting and reliable system design

Tape Caster systems developed in line with these principles are safely used in both R&D and industrial production environments.

Working Principle of the Tape Caster
The operating principle of Tape Caster systems consists of several basic stages:

Slurry Preparation:
Ceramic or similar materials are brought to a specific viscosity using binders and solvents.

Casting:
The prepared slurry is cast in a controlled manner onto the carrier surface.

Thickness Adjustment:
The cast material is adjusted to the desired thickness using the doctor blade.

Drying:
The cast layer is dried under controlled environmental conditions.

Cutting and Collection:
The dried tape is cut to the required dimensions and transferred to the next stage of the production process.

DMR Tekno Tape Caster systems control all these stages with high precision to achieve high-quality and repeatable results.

Critical Parameters in Tape Caster Design
The success of Tape Caster systems depends on technical parameters considered during the design phase. DMR Tekno analyzes these parameters in detail for each project.

Casting Thickness
Thickness adjustment directly affects the mechanical and functional properties of the product. Micron-level control is achieved with precision blade mechanisms.

Slurry Properties
Viscosity, particle distribution, and binder ratio form the basis of the design.

Belt Speed
A key parameter that determines production capacity and drying time.

Environmental Conditions
Temperature, humidity, and airflow directly affect drying quality.

Mechanical Structure and Stability
Mechanical stability is critical for layer homogeneity in Tape Caster systems. Vibrations or mechanical oscillations may cause surface waviness and thickness variations.

In DMR Tekno Tape Caster systems:

• High-rigidity chassis design

• Precisely adjustable blade mechanisms

• Low-vibration drive systems

are used to create a stable and reliable structure.

Doctor Blade and Adjustment Mechanisms
The doctor blade is one of the most critical components of Tape Caster systems. DMR Tekno designs blade mechanisms with high-precision adjustability.

Features of blade systems:

• Micron-level thickness adjustment

• Easy and quick adjustment capability

• Long-lasting material structure

This structure enables fast changeovers and flexible production for different products.

Carrier Belt and Surface Selection
The carrier belt or surface used in Tape Caster systems directly affects product quality. DMR Tekno offers different surface options depending on the application.

Available surface types:

• Stainless steel belts

• Polymer-based carriers

• Special coated surfaces

These options enable safe and high-quality casting of different materials.

Automation and Control Systems
DMR Tekno Tape Caster systems are equipped with advanced automation infrastructures. All process parameters are precisely managed through PLC- and HMI-based control systems.

Advantages provided by automation systems:

• Belt speed control

• Blade position adjustment

• Drying time monitoring

• Recipe-based production

• Data logging and reporting

These features ensure standardization and traceability in production.

Energy Efficiency and Drying Systems
The drying stage accounts for a significant portion of energy consumption in Tape Caster systems. DMR Tekno offers optimized drying solutions to improve energy efficiency.

Energy efficiency approach:

• Controlled airflow

• Optimal temperature distribution

• Designs that minimize heat losses

This reduces operating costs while minimizing environmental impact.

Sectoral Applications

Ceramics Industry
Widely used for technical ceramics, substrates, and thin layers.

Electronics and Semiconductors
An ideal solution for sensors, circuit substrates, and functional coatings.

Energy and Battery Technologies
Provides high precision in the production of electrodes and separator layers.

R&D and Laboratory Applications
Offers flexibility for new material development and prototyping.

Laboratory and Industrial Tape Caster Solutions
DMR Tekno develops Tape Caster systems suitable for both laboratory scale and industrial mass production.

Laboratory-Type Tape Caster

• Narrow belt width

• High precision

• Ideal for R&D and pilot studies

Industrial-Type Tape Caster

• Wide belt structure

• High production capacity

• Automatic loading and collection systems

Production, Assembly, and Testing Processes
DMR Tekno Tape Caster systems undergo detailed quality controls during production. After assembly, systems are subjected to comprehensive testing.

Testing processes include:

• Thickness homogeneity

• Mechanical stability

• Drying performance

• Automation functions

These tests guarantee the delivery of reliable and trouble-free systems to the field.

Commissioning and Training
Installation and commissioning of the systems are carried out by DMR Tekno’s technical team. Operators are provided with detailed training on use, maintenance, and safety.

After-Sales Support
DMR Tekno considers after-sales support an integral part of Tape Caster projects.

Services provided:

• Technical service

• Remote support

• Spare parts supply

• System revisions and improvements

Advantages of DMR Tekno Tape Caster Systems

• High thickness precision

• Stable and vibration-free structure

• Project-specific design

• Advanced automation infrastructure

• Long-term technical support