Roll-to-roll (R2R) solution processing of thin film devices offers savings to cost, time, and material waste. Emerging technologies in electronics, optoelectronics, and microfluidics could potentially benefit from these manufacturing advantages. However, the associated complex pattern requirements are difficult to attain with traditional solution-based methods, barring significant concessions to device performance and process scalability. In this paper, we present and implement a novel hybridization of continuous (e.g., slot die) and on-demand (e.g., inkjet) techniques designed to address these shortcomings, wherein. outflow from localized regions of an extrusion die is actuated in real time to produce patterns. Pattern features were produced with aqueous solutions of poly(vinyl alcohol) (PVA), and poly(3,4-ethyl-enedioxythiophene):poly(styrene sulfonate) (PEDOT:PSS), and deposition phenomena were observed in situ using a specialized roll feed imaging system. Minimum feature size is shown to be directionally dependent, with transient flow effects dominating along the axis coincident with substrate motion, and sensitive to several process inputs as well as coating material properties. Strategies for managing residual fluid in the die cavity and beneath the die lip are illustrated, through flow actuation mechanisms and exploitation of deposition phenomena, to optimize pattern fidelity. (C) 2016 Elsevier B.V. All rights reserved.