This project was carried out for an advanced research facility development center to build and apply CFD capability for analyzing microdroplet impact on microstructured surfaces. Both 2D and 3D simulations were performed using the Volume of Fluid (VOF) method to capture droplet impact, spreading, recoil, surface contact, and rebound across different surface geometries and operating conditions.
The simulations were used to understand how impact velocity, wettability, and microscale surface structure affect droplet deformation, spreading area, residence time, and rebound behavior. This provided practical insight for selecting and improving surface configurations intended for applications such as spray cooling, precision coating, microfluidics, semiconductor processing, and advanced thermal-management systems.
By comparing multiple surface designs computationally before fabrication and physical testing, the project helped reduce unnecessary experimental iterations and gave the facility a more efficient way to evaluate droplet–surface interactions during research and technology development.
The accompanying videos show both 2D and 3D CFD simulations for different microstructured surface configurations.
Contact CFD Vision to discuss multiphase CFD, microdroplet simulation, or advanced research and development projects.