New design method based on CFD and AM technology was applied to milli-reactors. CFD simulations were validated empirically with step responses and model reactions. 4-way inlet reactor with zigzag mixing channel showed the best mixing performance.
a b s t r a c tThe mixing performance of three passive milli-scale reactors with different geometries was investigated at different Reynolds numbers. The effects of design and operating characteristics such as mixing channel shape and volume flow rate were investigated. The main objective of this work was to demonstrate a process design method that uses on Computational Fluid Dynamics (CFD) for modeling and Additive Manufacturing (AM) technology for manufacture. The reactors were designed and simulated using SolidWorks and Fluent 15.0 software, respectively. Manufacturing of the devices was performed with an EOS M-series AM system.Step response experiments with distilled Millipore water and sodium hydroxide solution provided time-dependent concentration profiles. Villermaux-Dushman reaction experiments were also conducted for additional verification of CFD results and for mixing efficiency evaluation of the different geometries. Time-dependent concentration data and reaction evaluation showed that the performance of the AM-manufactured reactors matched the CFD results reasonably well. The proposed design method allows the implementation of new and innovative solutions, especially in the process design phase, for industrial scale reactor technologies. In addition, rapid implementation is another advantage due to the virtual flow design and due to the fast manufacturing which uses the same geometric file formats.
The RepRap 3D printer development project is a fast growing, open-hardware initiative relying on the input of hobbyist designers. One of its key components is the printer nozzle. The performance and reliability deficiencies of currently available nozzle designs are common topics in the RepRap community, and our own experience with a RepRap 3D printer has identified a need for improvement in a few particular areas. We set out to eliminate melt leakage, improve thermal isolation, and develop a more effective method of nozzle assembly attachment. Here, we review the issues, describe design efforts, and report results.
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