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Related Experiment Video

Updated: Jun 27, 2026

Microfluidic Fabrication Techniques for High-Pressure Testing of Microscale Supercritical CO2 Foam Transport in Fractured Unconventional Reservoirs

Microfluidic Fabrication Techniques for High-Pressure Testing of Microscale Supercritical CO₂ Foam Transport in Fractured Unconventional Reservoirs

Published on: July 2, 2020

Introduction of Micro-Scale CFD Model of Foam Injection Moulding Process.

Daniel C Fritsche¹, Malte Schön², Christian Hopmann¹

¹Chair of Plastics Processing, Rheinisch-Westfälische Technische Hochschule Aachen University, Seffenter Weg 201, 52074 Aachen, Germany.

|June 26, 2026

Summary

This summary is machine-generated.

This study introduces a micro-scale computational fluid dynamics (CFD) framework for foam injection moulding (FIM) to simulate bubble formation. The model captures gas-melt interactions and predicts microstructure evolution, offering insights into lightweight part development.

Keywords:

OpenFOAM bubble deformation cell growth kinetics classical nucleation theory (CNT)coalescence foam injection moulding (FIM)microcellular foaming multiscale simulation volume of fluid (VoF)

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Last Updated: Jun 27, 2026

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A Soft Tooling Process Chain for Injection Molding of a 3D Component with Micro Pillars

A Soft Tooling Process Chain for Injection Molding of a 3D Component with Micro Pillars

Published on: August 4, 2018

Area of Science:

Materials Science
Computational Fluid Dynamics
Polymer Processing

Background:

Current foam injection moulding (FIM) simulations lack microstructural detail.
Understanding bubble formation is crucial for optimizing lightweight thermoplastic parts.

Purpose of the Study:

To develop a micro-scale CFD framework for FIM that resolves gas-melt interactions and bubble morphology.
To investigate bubble nucleation, deformation, coalescence, and interaction during the FIM process.

Main Methods:

A two-phase, compressible volume-of-fluid solver (OpenFOAM) was employed.
Surface tension and viscoelastic Phan-Thien-Tanner rheology were incorporated.
A nucleation pre-processor based on classical nucleation theory was coupled with stochastic bubble placement.

Main Results:

The framework successfully reproduced characteristic morphology trends across the thickness of a plate geometry.
Predicted bubble aspect ratio and orientation align with expected skin-core behavior and experimental observations.
The simulations demonstrated the framework's ability to describe morphology development beyond simple spherical-cell assumptions.

Conclusions:

The developed micro-scale CFD framework provides a proof of concept for multiscale coupling in FIM.
It enables a more detailed understanding of micro-scale foam structure evolution based on macro-scale process conditions.
Further development requires a physically based mass-transfer model for accurate bubble growth kinetics.