Tensioned-web-over-slot die coating (TWOSD) takes advantages of the elastohydrodynamic interaction between the curved web under tension and the coating liquid to sustain a very small coating gap that enables ultra thin coating at relatively high speed. When the product requires two liquid layers, dual slot TWOSD coating can be used to coat those layers simultaneously. In this case, the liquid pressure along the coating bead sets not only the web configuration and meniscus locations but also the interlayer separation point. An easy way to control the pressure distribution is through the die lip geometry. Here, we analyze the effect of four different die lip geometric parameters, e.g. the downstream lip radius, the mid lip radius, the downstream lip offset and the mid lip apex point, on the coating window of the dual slot TWOSD coating. Using the model proposed by Nam and Carvalho (2009c) and a direct tracking of flow features, the boundaries of the vortex-free operating window, area inside the parameter spaces that ensure a uniform coating without vortex inside the flow, were obtained and compared for each die lip configuration. We found that the mid lip radius is one of the important parameters to control the location of the upstream meniscus. Also the location of the interlayer separation point can be controlled by the lip offset and location of the apex point. (C) 2010 Elsevier Ltd. All rights reserved.