Nonisothermal two‐dimensional film casting of a viscous polymer

Abstract A model is presented for simulating two‐dimensional, nonisothermal film casting of a viscous polymer. The model accommodates the effects of inertia and gravity, and allows the thickness of the film to vary across the width, but it excludes film sag and die swell. Based on the simulation results, three factors are shown to contribute to reducing neck‐in and promoting a uniform thickness: the self‐weight of the material, for low viscosity polymers; nonuniform thickness and/or velocity profiles at the die; and cooling of the film, especially when localized cooling jets are employed.