From imaging to simulation: A workflow for converting CT/SEM data into OpenFOAM meshes

¹ Heat Transfer and Fluid Flow Laboratory, Faculty of Mechanical Engineering, Brno University of Technology, Antoninska 548/1, 602 00 Brno, Czechia
² Christian-Doppler Laboratory for Metallurgical Applications of Magnetohydrodynamics, Dept. of Metallurgy, Montanuniversitaet Leoben, Franz-Joseph Strasse 18, 8700 Leoben, Austria.
³ Centro de Energías Renovables y Alternativas, Facultad de Ingeniería Mecánica y Ciencias de la Producción, Escuela Superior Politécnica del Litoral, Guayaquil, Ecuador

^* Corresponding author: This email address is being protected from spambots. You need JavaScript enabled to view it.

Published online: 12 March 2026

Abstract

CT and SEM imaging often produce complex geometries, such as porous or irregular structures, which pose significant challenges for numerical simulations. In contrast to meshless methods like LBM or SPH, traditional FVM and FEM solvers require a high-quality computational mesh with consistent connectivity — a task that becomes particularly demanding for image-based data.This work presents a practical, step-by-step workflow for converting CT or SEM datasets into simulation-ready meshes for OpenFOAM. Two alternative meshing strategies are introduced, each discussed in terms of workflow complexity, mesh quality, and computational efficiency. The study aims to simplify the integration of experimental imaging and CFD modeling, bridging the gap between real microstructures and numerical analysis.