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Extrudia · A Brinko platform

Qualify extrusion in software, not on the line.

Extrudia models how drug-loaded polymers, bioinks and biomaterial pastes flow, heat and swell through your dies and screws. Process teams lock in tooling and process windows before the first physical run.

Request a consultation See enterprise use cases

Typical results across deployments

fewer physical trial runs
72%fewer physical trial runs
pressure-drop error vs. line data
±3.1%pressure-drop error vs. line data
to a validated model
4 wkto a validated model
W 112.00 mmH 84.60 mmEXIT →Q 4.2 kg/hv_max 0.84 m/sτ_w 1.21 kPa0.000.84 m/s
Melt-flow velocity field across die land. Non-Newtonian, power-law n = 0.42.Δp 12.6 MPa

Extrudia models run inside R&D, process and manufacturing teams at

  • Pfizer
  • Merck
  • Thermo Fisher
  • Genentech
  • Novartis
  • BASF
  • Siemens Healthineers
  • Dow
  • Medtronic
  • Lockheed Martin
§ 01Product

This is Extrudia.

Watch the melt move through your die.

Velocity, temperature, shear and pressure across every section, checked against your own line sensors.

§ 02Enterprise use cases

Where Extrudia
earns its keep.

Every extrusion line runs on expensive material, scarce pilot time and tooling that takes weeks to remake. These are the four programs where enterprise teams use Extrudia most.

01Pharma formulation and process development

Hot-melt extrusion for oral solid dose

Problem
The API degrades or the amorphous dispersion turns inconsistent when you scale from an 11 mm to a 27 mm twin-screw.
Extrudia models
Residence time, melt temperature and specific mechanical energy, element by element along the screw.
Outcome
Screw configuration and process window defined before the first scale-up batch.
02Medical device and specialty pharma

Drug-eluting implants and long-acting injectables

Problem
Die swell and draw-down push implant diameter out of tolerance, which changes the drug release profile.
Extrudia models
Viscoelastic die swell, relaxation and cooling for PLGA, EVA and silicone systems.
Outcome
Die geometry that holds ±25 µm on the first cut.
03Regenerative medicine and tissue engineering

3D bioprinting and bioinks

Problem
Nozzle shear kills cells, and pressure and nozzle settings are found by trial and error.
Extrudia models
Yield-stress flow, wall shear stress and cell exposure time through the full nozzle path.
Outcome
Print parameters that keep shear below your viability threshold.
04Device manufacturers and contract extruders

Medical tubing and multi-lumen catheters

Problem
Lumens collapse and wall thickness drifts across complex multi-lumen profiles.
Extrudia models
Flow balance across the die, pin position and internal air pressure.
Outcome
Balanced die designs with fewer tooling iterations.
§ 03Platform

Five modules.
One validated model.

Extrudia is deployed and configured by our scientific team for each enterprise. Access is arranged through a consultation.

  1. M1

    Rheology Ingest

    Import rheometer and capillary data. Extrudia fits the right constitutive model automatically and flags gaps in your test matrix.

  2. M2

    Flow Solver

    3D non-Newtonian, non-isothermal finite-element solver with free-surface die swell. GPU-accelerated.

  3. M3

    Die & Screw Studio

    Bring your own CAD or build parametric dies and twin-screw element stacks inside Extrudia.

  4. M4

    Process Window

    Map the design space against your critical quality attributes, ready for QbD documentation.

  5. M5

    Validation Vault

    Every model version, input and result kept under audit trail with electronic signatures.

Technical specificationExtrudia
Material models
Power-law, Carreau-Yasuda, Cross, Herschel-Bulkley, Giesekus, PTT
Physics
Non-isothermal flow, viscous heating, wall slip, free-surface die swell
Geometry
STEP, IGES, Parasolid, STL. Parametric die and screw libraries
Compute
Managed GPU cloud, private VPC or on-prem HPC
Integrations
LIMS, ELN, MES, PI historian, Python SDK, REST API
Compliance
21 CFR Part 11, EU Annex 11, GAMP 5 validation package
Security
SSO (SAML, OIDC), role-based access, customer-managed keys
§ 04Results

Measured on real lines,
not in slides.

simulations solved on Extrudia
2.8Msimulations solved on Extrudia
fewer physical trial runs
72%fewer physical trial runs
median yearly savings per deployment
$1.9Mmedian yearly savings per deployment
enterprise deployments in 11 countries
38enterprise deployments in 11 countries
“Our last three implant programs hit spec on the first cut. We show up to the line with a die that is already right.”
Director of Process EngineeringGlobal medical device manufacturer
§ 05How a deployment works

From first call to a validated model.

  1. 01

    Consultation

    We review your materials, your equipment and the decision you need the model to support.

    One session

  2. 02

    Scoping under NDA

    We agree on the use case, the data you will share and the success criteria with your process team.

    1 to 2 weeks

  3. 03

    Pilot validation

    Extrudia is calibrated on your rheology and checked against your own line data.

    4 to 6 weeks

  4. 04

    Enterprise rollout

    Deployment to your environment, team training and a dedicated scientific contact.

    Ongoing

§ 06Brinko incubator

What our team is
building next.

Brinko is a holding group. Alongside Extrudia, our scientists and engineers are incubating these platforms. Design partners get early access and shape the roadmap.

  • BR-02Prototype with design partners

    Lattice

    Solid-state form screening

    Problem
    A polymorph discovered late in development can force reformulation and delay a filing.
    Approach
    Crystal structure prediction and lattice-energy ranking, refined with each partner's lab results.
    Built for
    Pharma solid-state and preformulation teams
    Become a design partner
  • BR-03Research

    Kinetiq

    Bioreactor scale-up

    Problem
    Cell culture that performs at 2 L often behaves differently at 2,000 L.
    Approach
    Hybrid mechanistic and machine-learning kinetics, informed by mixing and oxygen transfer simulation.
    Built for
    Upstream bioprocess teams and CDMOs
    Become a design partner
  • BR-04Design partner pilot

    Coldline

    Cryogenic logistics

    Problem
    Temperature excursions in transit put high-value cell and gene therapy doses at risk.
    Approach
    Lane-by-lane thermal simulation of shippers, dewars and every handoff point.
    Built for
    Cell and gene therapy manufacturers, specialty couriers
    Become a design partner
  • BR-05Prototype

    Provenance

    Lab data integrity

    Problem
    Audit trails are often reconstructed after the fact, right before an inspection.
    Approach
    Lineage for every sample, instrument and analysis, captured at the source and never edited.
    Built for
    QA and QC labs in GxP environments
    Become a design partner
  • BR-06Research

    Microflux

    Microfluidics design

    Problem
    Each microfluidic chip design can take several fabrication rounds to get right.
    Approach
    Solver-backed channel design with droplet and particle tracking before fabrication.
    Built for
    Diagnostics and organ-on-chip developers
    Become a design partner
  • Open slot

    Your problem here

    Have a technical problem no software solves well? Bring it to a consultation. Some of our best platforms started that way.

    Start a conversation →
§ 07Consultation

Tell us what
you’re extruding.

Every request is read by a Brinko scientist. We’ll come back with questions about your material and line, then set up a private consultation.

Format
Video call or on site
Confidentiality
Mutual NDA on request
First call
Complimentary, with a Brinko scientist
Form BR-C1Consultation request

Submissions are confidential and never shared.