Industrial microfluidic digital twins
- Problem
- Reliable filling of industrial microstructures depends on coupled effects that cannot be reduced to one filling-regime map: contact-line motion, edge pinning, channel and cavity geometry, capillary forcing, and numerical parasitic currents.
- Approach
- Connect controlled Bosch experiments, automated interface and contact-angle analysis, verified numerical stabilization, and three-dimensional geometric-VOF simulations in one traceable experiment-to-model evidence chain.
- Evidence
- Four peer-reviewed studies establish stable capillary-flow simulation, validated dynamic-wetting measurements, geometry-resolved pinning and penetration at T-junctions, and experiment-validated microcavity filling regimes.
- My role
- Principal Investigator and primary supervisor in the Bosch-funded doctoral research; numerical-method, simulation, software, and publication leadership.
- Decision supported
- Compare microchannel and cavity geometries and operating conditions against observed wetting, pinning, penetration, and gas-entrapment regimes.
- Team receives
- Validated image-analysis methods, reproducible CFD cases, numerical-stability guidance, and an evidence map linking observations to simulation assumptions.
- Current maturity
- Peer-reviewed industrial microfluidics evidence base spanning four connected studies; application-specific deployment is governed by a defined operating envelope and validation plan.
Public collaborations: Bosch. Names indicate publicly documented collaboration, not endorsement.
J7 · 2024 · Nagel et al.
Stable capillary-flow simulation
Artificial interface viscosity suppresses parasitic currents by about one order of magnitude while retaining the measured interface progression.
J10 · 2024 · Zhang et al.
Measured dynamic wetting in curved channels
Automated, validated image analysis measures interface motion and dynamic contact angles and tests competing wetting models.
J12 · 2024 · Zhang et al.
Pinning and penetration at T-junctions
Experiments quantify how crevice width, edge rounding, and flow rate govern interface pinning and penetration.
J5 · 2025 · Nagel et al.
Predictive microcavity filling regimes
Three-dimensional VOF and high-speed experiments resolve transient cavity filling and the onset of gas entrapment.
