01 / 02 — CAPABILITIES
We connect material, process, equipment, and support so R&D teams can move from a constrained sample to a defensible configuration and a repeatable workflow.
Start with a TrialTurn a material and target output into a complete processing configuration.
We work through screw configuration, length-to-diameter ratio, thermal profile, feeder selection, material contact surfaces, controls, and downstream equipment as one system. The goal is a configuration that reflects the formulation, available material, desired product form, cleaning strategy, and future scale—not a collection of disconnected components.
Generate the evidence needed to make the next equipment or formulation decision.
In our Piscataway lab, feasibility and development programs can evaluate feeding behavior, screw geometry, temperature, torque, residence time, extrusion stability, and downstream handling. Engagements are scoped around defined questions and can deliver process parameters, a trial report, configuration recommendations, and processed sample material for your own analysis.
Engineer around material, environment, containment, and output constraints.
Some programs need more than a standard catalog configuration. We coordinate custom system requirements with the manufacturing team, including unusual feedstocks, specialized barrel access, recirculation, multiple feeding streams, integrated downstream handling, remote operation, and hazardous-area requirements. Examples include ATEX-classified extrusion and ceramic injection-molding feedstock lines.
Receive processed material when owning equipment is not yet the right step.
For formulation screening, customer samples, method transfer, or bridging needs, the Test Lab can scope small-batch processing on the micro-extrusion platform. We align the run plan, material quantities, attendance format, deliverables, and sample disposition before work begins. Confidential projects can be handled under an agreed NDA.
Connect the extrusion process to the product form and downstream workflow.
Die geometry, discharge behavior, cooling, cutting, winding, and cleaning access affect whether a stable melt becomes a useful sample. We help define tooling and downstream interfaces for strands, granules, film, fiber, and application-specific outputs, with configuration tied back to the material and process window.
A future capability for purpose-built research and process instruments.
Xceptional Instruments is developing this capability area around the measurement and workflow gaps that appear during formulation and process development. If your team has an instrumentation need that is not addressed by standard laboratory equipment, contact us to share the application and technical requirements.
