2026
Enhanced Numerical Modeling of Non-Newtonian Particle-Laden Flows: Insights from the Carreau-Yasuda Model in Circular Tubes
Medeu Amangeldi, Dongming Wei, Asma Perveen, Dichuan Zhang
PolymersDOI
Advanced Polymer Extrusion Die Engineering
Design, Simulate, and Validate
Extrusion Dies
with Confidence
We specialize in the multi-physics design of advanced polymer extrusion dies for thin film, sheet, injection molding and pipe manufacturing, combining decades of research expertise with patented methodologies to deliver manufacturable, validated solutions.
Patented Methods
Novel die design methodologies backed by RK patents
15+ Publications
Peer-reviewed research in polymer flow & die optimization
Global Collaboration
Industry & academic partnerships across Asia and Europe
About Us
What is KXTrude?
KXTrude is a high-technology start-up specializing in the multi-physics and multi-functional design of advanced polymer extrusion dies for thin film, sheet, and pipe manufacturing lines. We bridge the gap between cutting-edge academic research and industrial application, providing clients with validated, manufacturable die designs that optimize performance, material usage, and final product quality.
Our team is built on a foundation of deep, interdisciplinary expertise, bringing together decades of experience in applied mathematics, mechanical engineering, and material science. We are not just designers. We are innovators who have developed and patented novel methodologies for extrusion die design.
Multi-Physics Design
Integrating CFD, FEM, and FSI for holistic, validated extrusion die solutions.
Advanced Rheological Modeling
Power-law, Cross, Carreau-Yasuda, and Bingham plastic models for accurate flow prediction.
Patented Methodologies
Multiple Republic of Kazakhstan patents for novel flat slot die designs.
Research-Driven Innovation
Backed by peer-reviewed publications and funded research grants.
Our Credentials
Expertise & Capabilities
Our core capabilities span six interdisciplinary areas, each backed by funded research, international collaboration, and real-world engineering validation.
Advanced Computational Modeling
World-class expertise in Computational Fluid Dynamics (CFD), Finite Element Method (FEM), and Fluid-Structure Interaction (FSI). We use industry-standard software like ANSYS, COMSOL, Moldex3D and OpenFOAM, as well as proprietary in-house simulation codes to accurately model complex, non-Newtonian fluid flows within die manifolds and through the die lip.
Non-Newtonian Fluid Mechanics & Rheology
Our approach is built on a fundamental understanding of complex fluid behavior. We have developed and validated design methodologies for Power-law, Cross, Carreau-Yasuda, and Bingham plastic models, which are critical for accurately predicting the flow of polymer melts and ceramic slurries.
Multi-Physics Optimization
We integrate solid mechanics, thermodynamics, and fluid dynamics to create holistic designs. This includes analyzing the effects of temperature and viscous dissipation, and accounting for structural deflection to ensure real-world performance aligns with simulations. Our use of adjoint methods and response surface methodology enables true design optimization.
Proven R&D Track Record
Our leadership has a proven history of securing and executing significant research grants focused on extrusion die technology, funded by the Kazakhstan Ministry of Education and Science and Nazarbayev University. This is validated by multiple awarded Republic of Kazakhstan patents for novel flat slot die designs and design methodologies.
Industry & Academic Collaboration
Our expertise has been honed through close collaboration with academic institutions and industry partners. We have served as lead researchers on projects with international companies in China and Kazakhstan, and maintain active research partnerships with leading academics in polymer processing and advanced manufacturing across Europe.
Mentorship & Technical Leadership
Our senior engineers have extensive experience mentoring and training the next generation of engineers. This culture of deep technical understanding and rigorous problem-solving ensures that every project is approached with the highest level of intellectual rigor and attention to detail.
What We Offer
Our Services
We offer a complete, end-to-end design service for polymer processing dies, empowering clients with the tools to achieve superior product uniformity, reduce material waste, and accelerate time to market.
01
Die Flow Manifold Design & Optimization
We specialize in the design of coat-hanger and other manifold geometries that ensure uniform flow distribution across the entire die width. Our design methodology, built on constant shear rate principles and validated against 3D CFD, eliminates stagnation points and vortex formation.
02
Full Die Body CAD Design
Moving beyond the internal manifold, we provide complete CAD design files for the die body. These files are optimized for manufacturability and ready to be integrated into your production line.
03
Numerical Simulation & Validation
Our designs are never based on intuition alone. We provide comprehensive simulation reports including CFD analysis of flow velocity, pressure drop, and shear rate profiles; FEM structural analysis for die deflection; non-isothermal flow modeling; and particle-laden flow modeling for composites and additives.
04
Customizable for Diverse Materials
Our design methodologies are not limited to a single type of polymer. We tailor dies for standard thermoplastics (polypropylene, polyethylene), temperature-sensitive polymeric materials, non-Newtonian fluids with complex rheology, and ceramic slurries and composite mixtures.
05
Specialized Applications
Leveraging our advanced modeling capabilities, we design dies for specific, challenging applications, such as the creation of multi-layer films through co-extrusion feedblock systems.
KXTrude provides more than just a die design. We deliver a fully validated, physics-driven solution that elevates your manufacturing process from a point of uncertainty to a platform for precision, efficiency, and innovation.
Get in TouchManufacturing Partners
From Design to Production
Our international partners in high-precision die design and manufacturing.
Coating Tech Slot Dies
Eau Claire, Wisconsin, USA
Precision slot die design, development, and manufacturing for roll-to-roll coating applications.
Visit website
JC-Times
Zhejiang, China
Manufacturer of precision extrusion dies and ancillary equipment for plastic film, coating, and advanced material processing.
Visit websiteVisual Results
Simulation Gallery
Simulation outputs, die assembly views, and animations produced by our research team, showcasing the range of geometries and flow configurations we work with.
Velocity
Flow velocity field for the die with inlet setup.
Pressure
Pressure contour distribution for the die.
Velocity Isometric
Isometric velocity visualization for improved spatial insight.
Simulation View
Primary simulation view.
Velocity - Battery Separator
Velocity contours across the battery head separator die.
Pressure - Battery Separator
Pressure distribution in the separator geometry.
Velocity Isometric - Battery Separator
Isometric velocity field for the separator die.
Die Isometric - Battery Separator
Isometric die geometry render for the separator case.
Powered by Our Platform
KXTrude Engineering Platform
To deliver our services, we have developed a proprietary browser-based engineering platform that unifies die design, meshing, CFD simulation, and 3D result visualization into a single connected workflow.
Request a DemoStructured Stage Progression
Defined stages from inputs to results, so nothing is skipped.
Persistent Project State
All parameters and outputs saved per project. Pick up where you left off.
Design-to-CAD Generation
Computes profile outputs and generates CAD-oriented geometry data.
Meshing with Quality Inspection
Generate, inspect, and decompose volume meshes before running the solver.
Live Residual Streaming
Watch CFD convergence in real time as residual data streams to your browser.
Interactive 3D Viewers
Explore velocity, pressure, and mesh in VTK.js-powered 3D viewers.
See the platform in action — from project setup to simulation results
Research
Publications
Peer-reviewed publications by our team covering polymer flow simulation, die geometry optimization, and computational rheology. This body of work forms the research foundation behind our design services.
2024
Geometric improvement of the sheet/film extrusion die using Rabinowitsch-Mooney analysis
Amin Razeghiyadaki, Dongming Wei, Asma Perveen, Dichuan Zhang
The International Journal of Advanced Manufacturing TechnologyDOI
2024
Investigation of Co-Extrusion Using a Coat Hanger Die with Different Feedblock Cross-Section
Nurdaulet Sharipkhan, Omonini Clifford, Asma Perveen, Dichuan Zhang, Dongming Wei
Key Engineering MaterialsDOI
2024
Investigation of the Two-Channel Feedblock Zone in Co-Extrusion of Polymers
Nurdaulet Sharipkhan, Asma Perveen, Dichuan Zhang, Dong Ming Wei
Key Engineering MaterialsDOI
2023
Optimization of Non-Newtonian Flow through a Coat-Hanger Die Using the Adjoint Method
Dastan Igali, Omonini Clifford, Asma Perveen, Dichuan Zhang, Dongming Wei
DesignsDOI
Get in Touch
Contact Us
Interested in our die design services or a partnership? Reach out for a consultation, project inquiry, or technical discussion.
Contact Information
Address
School of Engineering and Digital Sciences
Nazarbayev University
Qabanbay Batyr Avenue 53
Astana, Kazakhstan
Phone
+7 (000) 000-0000