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2024 Conference Registration

Registration is now open for the FLOW-3D World Users Conference 2024 in Hamburg, Germany, June 10-12! Connect with FLOW-3D users around the world. Enjoy social events, a poster session, technical presentations, product development talks and free advanced training.

Modeling Laser-based Additive Manufacturing -- Skipped, No-index

Flow Science Receives the 2023 Flying 40

Flow Science has been named one of New Mexico Technology’s Flying 40 recipients for the last eight consecutive years. The Flying 40 awards recognize the forty fastest growing, locally-owned technology companies in New Mexico each year, highlighting the positive impact the tech sector has on growing and diversifying New Mexico’s economy.

New Insights: Process & Material Developments with Melt Pool Modeling -- Skipped, No-index

General Multiphysics Applications with FLOW-3D -- Skipped, No-index

A Life in CFD by Dr. C.W. "Tony" Hirt

Dr. C.W. "Tony" Hirt, the founder of Flow Science, discusses his life in CFD, starting with his time in the T-3 Group at LANL under the tutelage of Dr. Francis Harlow. These notes consist of personal remembrances, history, incremental advances, and a discussion of where CFD is today and where it will be in the future.

Host a FLOW-3D HYDRO Workshop

If your company is located in the US or Canada and is interested in hosting a FLOW-3D HYDRO workshop, please contact us. Hosts receive three free workshop registrations.

Flow Science Earns Family Friendly Business Award® at the GOLD Level

For the seventh year in a row, Flow Science has earned distinction for its workplace policies by Family Friendly New Mexico, a statewide initiative developed to recognize employers that have adopted policies that give New Mexico businesses an advantage in recruiting and retaining the best employees.

Conference Proceedings

Access technical proceedings from past user conferences to learn about the many real-world applications of FLOW-3D products and the recent and upcoming developments for the FLOW-3D product suite. The conference proceedings from the FLOW-3D World Users Conference 2023 are now available for download!

FLOW-3D World Users Conference 2024

Save the dates! We invite our customers from around the world to join us at the FLOW-3D World Users Conference 2024. The conference will be held at the Steigenberger Hotel  on June 10-12, 2024 in Hamburg, Germany.

FLOW-3D World Users Conference 2023

The FLOW-3D World Users Conference Proceedings are now available! We would like to thank our speakers whose contributions made for an informative and stimulating conference. Download product development talks and customer case studies.

Speakers Announced for the FLOW-3D World Users Conference 2023

Flow Science, Inc. has announced the speakers for its FLOW-3D World Users Conference 2023. Amusement park rides, sand dunes, and sinking bubbles are just a few of the unique and exciting ways FLOW-3D products have been applied at this year's users conference.

FLOW-3D Workshops

Previous slide Next slide Previous Next Workshops for Prospective FLOW-3D Users Our multiphysics and microfluidics workshops introduce FLOW-3D to engineers working in the fields of biotechnology, consumer product design, automotive and aerospace engineering, coating research, and more. Through a series of guided, hands-on exercises, our Multiphysics Workshops help you build hands-on CFD expertise and familiarize yourself […]

FLOW-3D Workshops: Multiphysics

Build hands-on CFD expertise and learn how you can use FLOW-3D's powerful multiphysics simulation capabilities to solve complex problems in support of industry needs.

Local Workshops

This workshop will will introduce you to the fundamentals of 3D CFD simulation and the core capabilities of FLOW-3D HYDRO. This workshop is local and in-person.

What's New in FLOW-3D POST

FLOW-3D POST 2023R1 features an updated ParaView engine with native MP4 support, a streamlined Linux installer with automatic dependency testing for easy installation, and support for Windows 11 and RHEL 8.

Speakers Announced

We are very pleased to announce the speakers for the FLOW-3D World Users Conference 2023! Applying CFD to amusement park rides, sand dunes and sinking bubbles are just a few of the unique and exciting topics at this year’s users conference.

Introductory Workshops

If you are new to CFD or to FLOW-3D HYDRO and want a broad overview of its capabilities, this workshop will introduce you to the fundamentals of 3D CFD simulation and the core capabilities of FLOW-3D HYDRO.

Hydraulics Workshops

If you are new to CFD or to FLOW-3D HYDRO and want a broad overview of its capabilities, this workshop will introduce you to the fundamentals of 3D CFD simulation and the core capabilities of FLOW-3D HYDRO.

FLOW-3D Academic Program Survey -- Skipped, No-index


At Flow Science we solve the world’s toughest CFD problems involving free surface flows, turbulence, heat transfer and fluid-structure interaction. We are looking for a creative and motivated individual to join our R&D team to work on our CFD software FLOW-3D AM and FLOW-3D WELD.

FLOW-3D World Users Conference 2023 to take place in Strasbourg, France

Flow Science, Inc. will hold the FLOW-3D World Users Conference 2023 on June 5-7, 2023 at the Sofitel Strasbourg Grande Ile in Strasbourg, France. This year’s conference features application-specific tracks, advanced training sessions, in-depth technical presentations by FLOW-3D users, and the latest product developments presented by Flow Science’s senior technical staff.

FLOW-3D (x) Workshop -- Skipped, No-index

2022R2 Product Release -- Skipped, No-index

Making The Mactaquac Dam New Again

A great deal of work remains before the Mactaquac Generating Station is restored. FLOW-3D HYDRO has allowed Hatch to identify the best approach moving forward, giving them a solid footing to plan and design future improvements and refurbishment. It allowed them to pinpoint the most effective way to improve hydraulic performance and reduce the risk of future erosion in the most efficient and cost-effective possible way.

USACE Garrison Dam Spillway Workshop -- Skipped, No-index

Announcing the FLOW-3D 2022R2 Product Family Release

Flow Science has released the FLOW-3D 2022R2 product family that includes FLOW-3D, FLOW-3D HYDRO and FLOW-3D CAST. In the 2022R2 release, Flow Science has unified the workstation and HPC versions of FLOW-3D to deliver a single solver engine capable of taking advantage of any type of hardware architecture, from single node CPU configurations to multi-node parallel high performance computing executions.

What's New in FLOW-3D CAST

With the release of the FLOW-3D CAST 2022R2 product family, Flow Science has unified the workstation and HPC versions of FLOW-3D CAST to deliver a single solver engine capable of taking advantage of any type of hardware architecture.

What's New in FLOW-3D HYDRO

With the release of the FLOW-3D HYDRO 2022R2 product family, Flow Science has unified the workstation and HPC versions of FLOW-3D HYDRO to deliver a single solver engine capable of taking advantage of any type of hardware architecture.

What's New in FLOW-3D

With the release of the FLOW-3D 2022R2 product family, Flow Science has unified the workstation and HPC versions of FLOW-3D to deliver a single solver engine capable of taking advantage of any type of hardware architecture.

What's New in FLOW-3D (x) 2022R1 -- Skipped, No-index

Optimization and Workflow Automation Software FLOW-3D (x) 2022R1 Released

Flow Science, Inc. has released FLOW-3D (x) 2022R1, an optimization and workflow automation software that integrates seamlessly with the FLOW-3D product family. FLOW-3D (x) offers a powerful platform for users to arrive at the best design solution, achieving greater certainty while reducing modeling and analysis time.

FLOW-3D HYDRO Workshops

Our FLOW-3D HYDRO workshops introduce the new FLOW-3D HYDRO software to civil and environmental engineers through guided, hands-on exercises.

What's New in FLOW-3D (x)

FLOW-3D (x) 2023R1 further streamlines the workflow in our integration, automation, and optimization software, making it easier to perform analyses than ever before.

Flow Science Receives the 2022 Flying 40

Flow Science has been named one of New Mexico Technology’s Flying 40 recipients for the last seven consecutive years. The New Mexico Technology Flying 40 awards recognize the 40 fastest growing technology companies in New Mexico each year, highlighting the positive impact the tech sector has on growing and diversifying New Mexico’s economy.

Learning CFD from Afar

Due to the broad design of my internship, I was exposed to an array of industries, physics concepts, and software features rather than focusing on one or two specific applications. Since similar physics phenomena are present across different engineering problems, learning a range of applications provided me with a more thorough understanding of which physics models are important to include and which are not for an effective simulation. Read more of Garrett Clyma's internship blog.

Why CFD?

Why do we use CFD? The basic reason is that computer simulations can do things that experiments and mathematical analysis cannot. Once validated as a source of decent approximations of physical observations, a numerical simulation program can provide detailed information about a fluid flow problem, such as densities, pressures, temperatures and velocities throughout a flow.

FLOW-3D WUC 2022 Feedback -- Skipped, No-index

Dr. Tony Hirt, Founder of Flow Science, Inc. Receives the John Campbell Award

Flow Science, Inc. founder Dr. C.W. “Tony” Hirt was awarded the prestigious John Campbell Medal from the Institute of Cast Metals Engineers. Dr. Hirt received the award for his unique, long-lasting contributions to the science and practice of metal casting through his development of the FLOW-3D and its casting-specific version, FLOW-3D CAST.

Optimization of a Sand Casting with FLOW-3D CAST

The goal of a casting simulation is to predict casting defects and find the corrective measures to avoid such defects. To achieve this, the casting simulation must accurately predict the physical results. In this article, we illustrate a validation of FLOW-3D CAST by comparing simulation results with experimental findings. For this validation, we selected an aluminum casting with significant porosity defects. The extent of the porosities meant that the casting would not fulfill the functional specification and would be rejected.

Speakers Announced

We are very pleased to announce the speakers for the FLOW-3D World Users Conference 2022! Users in industry and academia will present their work in metal casting, additive manufacturing, civil and environmental engineering, coastal structures, and maritime engineering. FLOW-3D engineers and associates will present on the latest features, upcoming developments, and future plans of FLOW-3D, and our esteemed keynote speaker Hubert Lang will share the 15-year history of FLOW-3D at BMW.

FLOW-3D Workshop Survey -- Skipped, No-index

Training Sessions at the FLOW-3D World Users Conference 2022

In conjunction with the FLOW-3D World Users Conference 2022, advanced training sessions will be held the afternoon of May 16 at the conference hotel. Taught by senior technical staff and experts in their fields, advanced training sessions include Version Up seminars for FLOW-3D CAST, FLOW-3D AM, FLOW-3D HYDRO and FLOW-3D as well as a FLOW-3D POST session focused on best practice workflows and commonly-asked support questions.

FLOW-3D World Users Conference 2022 to take place in Munich, Germany

Flow Science, Inc. will hold the FLOW-3D World Users Conference 2022 on May 16-18, 2022 at the Maritim Hotel in Munich, Germany. Co-hosted by Flow Science Deutschland, this year’s conference features application-specific tracks, advanced training sessions, in-depth technical customer presentations, and the latest product developments presented by Flow Science’s senior technical staff.

Dr. Flender Holding GmbH acquires Flow Science, Inc.

Dr. Flender Holding GmbH, owner of MAGMA Giessereitechnologie GmbH and SIGMA Engineering GmbH, acquired 100% of the shares of Flow Science, Inc. in December 2021. With its broad range of products and services, Flow Science will continue to operate as an independent company as part of the Dr. Flender Holding group.

Flow Science a NM Family Friendly Business Platinum

Flow Science, Inc. has earned Platinum level distinction for its workplace policies by Family Friendly New Mexico, a statewide initiative recognizing employers that have adopted policies that give New Mexico businesses an advantage in recruiting and retaining the best employees. This is Flow Science’s sixth year in a row winning a Family Friendly New Mexico award and second year in a row at the Platinum level.

Getting Started with FLOW-3D -- Skipped, No-index

Getting Started with FLOW-3D CAST -- Skipped, No-index

Getting Started with FLOW-3D HYDRO -- Skipped, No-index

Tailings Model -- Skipped, No-index

2022R1 Product Release -- Skipped, No-index

Announcing the 2022R1 FLOW-3D Product Release

Flow Science has launched the 2022R1 FLOW-3D product family release that includes FLOW-3D, FLOW-3D HYDRO and FLOW-3D CAST. The new versioning of FLOW-3D products reflects Flow Science’s adoption of a synchronized release naming convention and the transition to a unified code base for FLOW-3D products. This change will allow users access to the latest developments at a more frequent product release pace.


FLOW-3D CAST 2022R1 features expanded controls for Active Simulation Control, tabular properties that allow users to easily understand complex dependencies without the need to fit data to a curve, and new outputs for identifying filling defects such as local filling velocity, time and temperature.

Detailed Cutcell Representation

The fractional cell area and volume method, FAVOR™, enables FLOW-3D to efficiently simulate flow through and around user-defined geometry, without needing unstructured, body-fitted grids.

What's New in FLOW-3D 2022R1

The new 2022R1 versioning of FLOW-3D products reflects Flow Science’s adoption of a synchronized release naming convention for FLOW-3D, FLOW-3D CAST and FLOW-3D HYDRO. 2022R1 represents the transition to a unified code base for FLOW-3D products. This important evolution will allow users access the latest developments as soon as they are ready, at a more frequent product release pace.


The FLOW-3D HYDRO 2022R1 release features detailed cutcell representation, new dissolved oxygen and axial pump models, extensions to Active Simulation Control capabilities, and tabular properties.

Clarifiers and Aeration Tanks -- Skipped, No-index

Flow Science Receives the 2021 Flying 40

Among technology companies who were able to “weather the storm” caused by the coronavirus, Flow Science is named one of the fastest growing technology companies in New Mexico for the sixth year running.

Contact Tanks & Reaction Kinetics -- Skipped, No-index

Micro/Biofluidic Applications -- Skipped, No-index

Bell Housing: Gating and Runner Evaluation -- Skipped, No-index

ASDSO 2021 Workshop Licensing Form

Advanced Air/Water Applications -- Skipped, No-index

FLOW-3D HYDRO Webinars

Watch FLOW-3D HYDRO webinars on demand to learn about the CFD modeling solution for the civil and environmental engineering industry.

Air Entrainment Template -- Skipped, No-index

DTU Digital Twins for AM -- Skipped, No-index

Tailings Model

Managing and mitigating the risks associated with mine waste facilities are important to mining operators and stakeholders. A tailings flow runout assessment is used to understand the risk of potential failure to downstream infrastructure and environment.


Search Results Proof

Sediment Transport Webinar -- Skipped, No-index

Numerical Approximations for Partial Differential Equations

Mathematical models for continuum dynamic phenomena involve one or more partial differential equations. Constructing numerical approximation for these equations that can be used to obtain approximate solutions using computers requires some care.

Reconstruction and Extension of the Méricourt Locks: Study of Hydraulic Operations

The BRL ingénierie teams modeled the Mericourt locks using transient 3D CFD hydraulic analysis with FLOW-3D.

EREDOS PROJECT: Numerical Modeling of Flows in Covered Streams

As part of the EREDOS project, BRL ingenierie used FLOW-3D CFD software to numerically model the issues associated with covered streams.

Plumes, Scalar Transport and Density Flows -- Skipped, No-index


Watch FLOW-3D AM and FLOW-3D WELD webinars on demand to learn more about the power of simulation to improve process parameters.

FLOW-3D (x) Release Webinar -- Skipped, No-index

FLOW-3D (x): Connect, Automate, Optimize

In this blog, we’ll look at FLOW-3D (x)- a completely new product from Flow Science that will change the way you work with FLOW-3D products, make you more productive, improve your designs beyond what you thought was possible, and give you a deeper insight into your simulations than ever before.

Numerical Treatment of Incompressible Flow

The first (two dimensional) computational method for modeling incompressible fluids governed by the Navier-Stokes equations was published by Harlow and Welch in 1965. This method included a capability for general free surfaces existing in two-dimensional flows. In addition, the Harlow and Welch paper introduced the concept of a staggered computational grid, something that is now a common practice.

Metal Casting Simulation Services

Send us your geometry and process description to let us simulate your part for you, leveraging our experience and software strengths to help you improve your casting design.

Non-Laser Based Processes

FLOW-3D AM offers powder spreading and melt pool modeling tools based on discrete element method (DEM) and computational fluid dynamics (CFD) for AM processes.

Shallow Water/3D Hybrid Modeling -- Skipped, No-index

Flow Science Launches FLOW-3D (x)

Flow Science has launched FLOW-3D (x), an optimization and workflow automation software, the latest addition to the FLOW-3D product family.

FLOW-3D (x)

FLOW-3D (x) will dramatically change the way you do CFD, connecting automation, optimization, and batch-processing into your CFD workflow. FLOW-3D (x) lets you graphically and intuitively build automation and optimization as well as connect external nodes like Solidworks, Rhino and Excel to dynamically feed information into your simulation.

Melt Pool Modeling – Innovation in Laser Welding and Additive Manufacturing -- Skipped, No-index

Advanced Free Surface Modeling Techniques -- Skipped, No-index

Exploring Ray Tracing in FLOW-3D POST

In the world of CFD, we use FLOW-3D POST to learn about our processes, analyze, visualize, and communicate the results of our simulations. We can now use the ray tracing option to increase the quality of our images and videos.

Free surface modeling with FLOW-3D HYDRO -- Skipped, No-index

Communicate Your CFD Results with Confidence

The ability to visualize and present clear, meaningful analysis of simulation data is a crucial part of the CFD simulation process. In this blog, we'll explore some powerful features of FLOW-3D POST so that you can communicate your CFD results with confidence.

Good Hardware Means Improved FLOW-3D POST Experience

In this blog, Stephen Sanchez, GUI Developer/Manager, Software Engineering, gives his two cents on how you can obtain the optimal FLOW-3D POST experience by following these hardware recommendations.

Flow Science Earns Family Friendly Business Award® at the Platinum Level

Flow Science has earned Platinum level distinction for its workplace policies by Family Friendly New Mexico, a statewide initiative developed to recognize employers that have adopted policies that give New Mexico businesses an advantage in recruiting and retaining the best employees.

Time to Learn about FLOW-3D HYDRO -- Skipped, No-index


An advanced postprocessing tool, FLOW-3D POST delivers sophisticated visualization and analysis for all FLOW-3D products.

FLOW-3D Products

FLOW-3D products provide a complete and versatile CFD simulation platform for engineers investigating the dynamic behavior of liquids and gas in a wide range of industrial applications and physical processes.FLOW-3D’s state-of-the-art capabilities allow our customers around the world to solve the world’s toughest CFD problems.

FLOW-3D HYDRO Release Webinar -- Skipped, No-index

Simulation Video Gallery

Explore the many possibilities of what can be modeled with the FLOW-3D product family in our simulation video gallery.

Siphon Spillways

Northwest Hydraulics Consultants has applied CFD modeling in numerous case studies of existing or new spillway designs. The following article demonstrates a sample case study conducted on an existing siphon spillway.

Consumer Products

FLOW-3D's advanced multiphysics models including air entrainment, porous media, and surface tension make it easy to accurately simulate and optimize consumer product designs.


FLOW-3D has been used by coating researchers in industry and academia for machine design research, process window development, and optimization.

The Solid Proof: The Latest in Solidification Modeling

One of the most exciting new developments offered with the release of FLOW-3D CAST v5.1 is the new chemistry-based aluminum-silicon and aluminum-copper alloy solidification model. This new model allows users to predict the microstructure and mechanical properties for as-cast and heat-treated castings.


Engineers in the energy sector around the world face complex design challenges every day in a wide range of processes for which solutions can be found through computational fluid dynamics.


For engineers working in the field of aerospace, FLOW-3D provides valuable insight into fuel stability/ acquisition, cryogenic temperature regulation, PMDs, cavitation, and electric charge distribution through use of accurate liquid/gas interface (free-surface) modeling, thermal solutions with phase and electrostatics physical models.


An advanced simulation software, FLOW-3D AM analyzes and predicts melt-pool dynamics and solidification in AM processes such as laser powder bed fusion (LPBF) and directed energy deposition (DED).

The Next Frontier of Metal AM -- Skipped, No-index

Simulation of Joule Heating-based Core Drying

The new, patented Advanced Core Solution (ACS) process aims for time- and energy-efficient core drying and curing. The ACS process uses a property common to all inorganic binder systems: because they are water-based, they are electrically conductive.

Flow Science Receives the 2020 Flying 40

Flow Science has been named one of New Mexico Technology’s Flying 40 recipients for the last five consecutive years. The Flying 40 awards recognize the 40 fastest growing technology companies in New Mexico.


FLOW-3D CFD software offers simulation solutions to many of the challenges in the automotive industry.

Announcing the Launch of FLOW-3D HYDRO

FLOW-3D HYDRO features a streamlined, water-focused user interface and offers new simulation templates for efficient modeling workflows.


Applying computational fluid dynamics to the field of biotechnology is a relatively new practice and has great potential to improve the way many medical devices are used or implemented.


Engineers in the energy sector around the world face complex design challenges every day in a wide range of processes for which solutions can be found through computational fluid dynamics.

What's New in FLOW-3D HYDRO

FLOW-3D HYDRO’s new streamlined user interface focuses on the needs of the water community.

Conveyance Infrastructure

Moving water in and around cities offers some of the most exciting and challenging applications for CFD modelers. The hydraulics in these applications offer infinite variations of free surface and pressurized flow conditions, with sometimes extremely turbulent and energetic flows, in which considerations of the air phase, air entrainment and bulking, or grit and sediment movement are equally important.

Water Treatment

Water and wastewater recovery facilities offer a unique set of modeling challenges. Moving water through a treatment plant includes a mix of flow diversions, flow splitting, free surface and pressurized pipe flow conditions, with head loss and detailed velocity fields all important modeling outcomes. Other process modeling challenges include aeration, hindered settling, chemistry, and impeller motion.

Rivers and Environmental

FLOW-3D HYDRO can be used as an advanced modeling tool when 3D non-hydrostatic modeling capabilities are necessary to provide a greater degree of accuracy and model resolution. Typical modeling applications are related to small dams/infrastructure, transportation hydraulics, complex 3D river hydraulics, thermally buoyant plumes, outfalls and contaminant transport.

Ports and Coastal

Port, coastal, and maritime engineering involves challenging applications, ranging from major port redevelopment to coastal defenses and environmental analysis. Engineers working in these application areas must solve problems involving complex interactions between waves, structures, erosion, air entrainment, and variable density flows.

Getting Started with FLOW-3D -- Skipped, No-index

Dams and Spillways

Hydroelectric power projects are sensitive to three-dimensional flow effects, and accurately predicting flow patterns is important for maximizing efficiency. FLOW-3D HYDRO is an industry leader in free-surface flow modeling and is used by dam professionals to address a wide range of design problems for existing and proposed projects.

Chemistry-based Solidification Webinar -- Skipped, No-index

CFD Simulations for Laser Welding -- Skipped, No-index

CFD for Additive Manufacturing Simulations -- Skipped, No-index

FLOW-3D Workshop Terms and Conditions -- Skipped, No-index


FLOW-3D HYDRO is the complete CFD modeling solution for the civil and environmental engineering industry. FLOW-3D HYDRO features a streamlined, water-focused user interface and offers new simulation templates for efficient modeling workflows, as well as expanded training materials geared to the needs of the civil or environmental engineer.

Code of Conduct

From its founding in 1980, Flow Science has placed great value in its employees and strived to insure that the needs of its customers were well-met. Flow Science’s products, and the services provided in support, are by their very nature designed to enable scientists and engineers to contribute to sustainable development and environmental sensitivity.


FLOW-3D WELD provides powerful insights into laser welding processes to achieve process optimization.

Achieving Optimal Continuous Castings

Using the continuous casting process, casters can manufacture ingots, high-pressure tubes, and irregularly-shaped bars of high quality and strength, but the process must be controlled through a delicate balance of pour temperature, mold cooling, and draw rate.

Volume of Fluid (VOF) History

The Volume of Fluid (VOF) method is based on the earlier Marker-and-Cell (MAC) method.

Sand Core Making - Is It Time to Vent?

Sand cores are a crucial element in the casting process because they are used to create complex interior cavities. In this blog I will walk you through the process of how sand cores are made and describe the modeling tools in FLOW-3D CAST v5.1 that help engineers design their manufacturing processes.

Exploring the Centrifugal Casting Workspace

In this blog, we will explore the three centrifugal casting processes – horizontal, vertical, and centrifuge – available in FLOW-3D CAST v5.1’s Centrifugal Casting Workspace and its unique features that allow casting engineers to create high quality castings.

End-User License Agreement -- Skipped, No-index

Simulating the Investment Casting Process

FLOW-3D CAST v5.1's Investment Casting Workspace provides the necessary tools to study the wide range of process parameters in a virtual space and determine an optimal design before casting a single part. In this blog, we’ll walk through the Investment Casting Workspace and show how easy it is to simulate a directionally-cooled investment casting using a Bridgman process.

Modeling Laser Welding with FLOW-3D WELD

FLOW-3D WELD is a powerful, multi-physics simulation software dedicated to modelling the complex phenomena in laser-based processes such as welding, brazing, soldering, cladding, and dissimilar metal joining. FLOW-3D WELD is used by industry and academic researchers to explore the effects of material properties, laser process parameters and shield gas effects on the evolution of the melt pool and associated defects common to the various laser based processes.

FLOW-3D CAST v5.1 Released

Flow Science has announced a major release of their metal casting simulation software, FLOW-3D CAST v5.1, a modeling platform that combines extraordinary accuracy with versatility, ease of use, and high performance cloud computing.

FLOW-3D CAST Webinars

Watch FLOW-3D CAST Webinars on Demand!

FLOW-3D Workshops: Additive Manufacturing

Our FLOW-3D AM workshops provide thorough, hands-on instruction in FLOW-3D AM's interface and modeling capabilities, leaving you with a clear understanding of how FLOW-3D AM can benefit your own additive manufacturing and laser welding research.

FLOW-3D Workshops

FLOW-3D Workshops are online and in-person, with opportunities across the world tailored to water & environmental, metal casting, and microfluidics industries.

Modeling Liquid Film Coating with FLOW-3D -- Skipped, No-index

FLOW-3D Workshops: Microfluidics

Our FLOW-3D workshops deliver focused, hands-on, yet wide-ranging instruction that will leave you with a thorough understanding of how FLOW-3D is used in microfluidics research.

Activated Sludge Modeling: Part II

In this blog, I will show FLOW-3D’s ASM solver results for the decay and growth of various influent species concentrations as they exit a wastewater treatment plant (WWTP) in Zele, Belgium.

Community Outreach

Over the years, we have contributed to the Santa Fe community by sponsoring and participating in March for Science, volunteering for Hour of Code and promoting other STEM events. In addition to our education outreach, Flow Science supports organizations working to improve lives and end homelessness and hunger in northern New Mexico, including the Food Depot, Kitchen Angels and St. Elizabeth’s Shelter.

What's New in FLOW-3D CAST v5.1

FLOW-3D CAST v5.1 includes new process workspaces for investment casting, sand core making, centrifugal casting, and continuous casting, an expansive database of exothermic risers, and a brand new, chemistry-based alloy solidification model.

Flow Science Earns Recognition as New Mexico Family-Friendly Workplace

For the fourth year in a row, Flow Science, Inc. has earned gold distinction for its workplace policies by Family Friendly New Mexico.

Activated Sludge Modeling: Part I

A detailed understanding of the biochemical reactions and hydrodynamics inside wastewater treatment plants (WWTPs) can assist designers and engineers in evaluating new plant designs, quantifying management decisions, developing new control schemes and providing safe operator training. In this blog, I will introduce our readers to FLOW-3D’s new Activated Sludge Model (ASM) which dynamically solves massive systems of biochemical reactions.

Advanced Metal Casting Process Workspaces in FLOW-3D CAST v5.1

This webinar reviews the different modeling Process Workspaces available in FLOW-3D CAST, with examples and illustrations about how these features are implemented in the user interface. In addition, we review the benefits of running FLOW-3D CAST on the CLOUD, where hundreds of CPU cores can be used to improve runtimes or run dozens of concurrent simulations, as needed on a per project basis.


FLOW-3D CAST is a state-of-the-art metal casting simulation modeling platform that combines extraordinarily accurate modeling with versatility, ease of use, and high performance CLOUD computing capabilities.

Lost Foam Casting Workspace

FLOW-3D CAST's Lost Foam Casting Workspace provides lost foam casters with all the tools needed to simulate the filling, solidification and cooling subprocesses.

Low Pressure Die Casting Workspace

FLOW-3D CAST's Low Pressure Die Casting Workspace is an intuitive modeling environment designed for engineers to successfully model low pressure die casting applications.

Gravity Die Casting Workspace

The Gravity Die Casting Workspace is an intuitive modeling environment designed to help engineers successfully model gravity die casting applications with FLOW-3D CAST.

Low Pressure Sand Casting Workspace

FLOW-3D CAST's Low Pressure Sand Casting (LPSC) Workspace provides an easy-to-use tool for simulating all the processes commonly used in the foundry.

Sand Casting Workspace

FLOW-3D CAST's Sand Casting Workspace provides sand casters with all the tools needed to simulate their filling, solidification, and cooling analyses.

High Pressure Die Casting Workspace

The High Pressure Die Casting Workspace is an intuitive modeling environment designed to help engineers successfully model high pressure die casting applications with FLOW-3D CAST.

Sand Core Making Workspace

FLOW-3D CAST's Sand Core Making Workspace provides users with an easy-to-use tool for modeling the shooting and hardening of sand cores.

Continuous Casting Workspace

FLOW-3D CAST's Continuous Casting Workspace provides continuous casting users with an easy-to-use tool for simulating all the commonly used foundry processes, including continuous billet casting as well as direct chill continuous casting.

Investment Casting Workspace

FLOW-3D CAST's Investment Casting Workspace provides investment casters with an easy-to-use tool for simulating all aspects of investment casting, including shell generation, filling, solidification, and cooling.

Tilt Pour Casting Workspace

The Tilt Pour Casting Workspace is an intuitive modeling environment designed to help engineers successfully model tilt pour casting applications with FLOW-3D CAST.

Centrifugal Casting Workspace

FLOW-3D CAST's Centrifugal Casting Workspace provides centrifugal casting users with an easy-to-use tool for simulating horizontal and vertical true centrifugal castings, semi-centrifugal castings, and centrifuge castings.

FLOW-3D Workshops: Brazil

Nossos workshops são projetadas para fornecer instruções focadas, práticas e abrangentes, que deixarão você com uma compreensão completa de como o FLOW-3D é usado nas principais industrias de água & meio ambiente assim como fundição de metais.

Licenciamento para o Workshop FLOW-3D

FLOW-3D v12.0 HPC Release -- Skipped, No-index

FLOW-3D World Users Conference 2020 Conference Announced

In conjunction with its 40th anniversary, Flow Science, Inc. will hold the FLOW-3D World Users Conference 2020 on June 8-10, 2020 at the Maritim Hotel in Munich, Germany.

Low Pressure Die Casting Workspace

In this technical webinar, metal casting engineer Ajit D’Brass reviews FLOW-3D CAST’s Low Pressure Die Casting Workspace. After reviewing the software’s fundamental modeling capabilities, an in-depth look at model setup in FLOW-3D CAST‘s graphical user interface will be highlighted.

FLOW-3D World Users Conference Registration

Register for the FLOW-3D World Users Conference 2023!

HPC Release of FLOW-3D v12.0

Flow Science, Inc. has announced that it has released the HPC-enabled FLOW-3D v12.0. The HPC version of FLOW-3D v12.0 can be run on in-house clusters or on the FLOW-3D CLOUD software as a service platform.

Gravity Die Casting Workspace -- Skipped, No-index

FLOW-3D AM: What's happening at the melt pool? -- Skipped, No-index

HPDC Workspace -- Skipped, No-index

Contact Line Pinning

A new contact line pinning model has been developed for the latest update of FLOW-3D v12.0, expanding the software’s capabilities to a wider range of surface-tension-dominated applications.

Hardware Selection for FLOW-3D Products

In this blog, Flow Science's IT Manager Matthew Taylor breaks down the different hardware components and suggests some ideal configurations for getting the most out of your FLOW-3D products.

Surface Skew Effects on Biofilms in Wastewater Treatment

The sensitivity of bacteria to physical, chemical and environmental disturbances presents a challenge to maintaining microbial nitrification in wastewater treatment plants. Researchers at the University of New Mexico conducted a series of experiments to understand the effects of surface roughness on annular nitrifying biofilm reactors (Roveto et al., 2019). Their team used FLOW-3D to find possible explanations for their experimental observations.

Flow Science Receives the 2019 Flying 40

Flow Science was named one of New Mexico Technology’s Flying 40 recipients yet again. The New Mexico Technology Flying 40 awards recognize the 40 fastest growing technology companies in New Mexico each year.

Tilt Pour Casting Workspace -- Skipped, No-index

User Conference Proceedings Available

Access technical proceedings from past user conferences to learn about the many real-world applications of FLOW-3D products and the recent and upcoming developments for the FLOW-3D product suite. The conference proceedings from the FLOW-3D European Users Conference 2019 are now available for download!

Learn and Teach CFD Better

At Flow Science we know that the quality of CFD education is an invaluable part of students’ success during their academic career and beyond. Our academic assistance program is designed to support the educational goals of participants and improve the quality of their research. Flow Science offers two academic assistance programs: the Research Assistance program and the Teaching Assistance program.

Flow Science Recognized as NM Family-Friendly Workplace

For the third year in a row, Flow Science, Inc. has earned distinction for its workplace policies by Family Friendly New Mexico, which give New Mexico businesses an edge in recruiting and retaining the best employees.

FLOW-3D European Users Conference 2019 Speakers Announced

Users will present original, innovative work featuring applications of FLOW-3D or FLOW-3D CAST in the fields of water & environmental engineering, automotive and aerospace design, biotechnology, additive manufacturing, and more.

Lost Foam Workspace -- Skipped, No-index

Coating Applications -- Skipped, No-index

Steady-State Accelerator for Free-Surface Flows

In this note, a simple pressure adjustment applied to free-surface cells acts as a damping force on surface disturbances. This damping accelerates the approach to a steady free-surface configuration.

FLOW-3D v12.0 Release Features Modern GUI -- Skipped, No-index

FLOW-3D CAST Case Studies

Identifying defects in metal castings, designing parts with new materials for lighter and stronger cast parts or doing iterative design work to come up with an optimal design are some of the ways that our customers use FLOW-3D CAST to help them meet the requirements of their jobs and save money.

FLOW-3D Water Infrastructure: 2019 Review -- Skipped, No-index

FLOW-3D v12.0

FLOW-3D v12.0 marks an important milestone in the design and functionality of the graphical user interface (GUI), which simplifies model setup and improves user workflows. A state-of-the-art Immersed Boundary Method brings greater accuracy to FLOW-3D v12.0’s solution.

Data Access Request

Enter your email to request Data.

Compact Disc Microfluidic Devices: Optimizing Real Estate

Optimizing the limited real estate in tiny microfluidic devices is important to satisfy the increasing expectations of the users of microfluidic devices. Users expect maximum functionality and multiple parallel operations from a single microfluidic device.


Learn more about events featuring the FLOW-3D family of products at one of our many workshops, webinars, and conferences online and around the world!

FLOW-3D European Users Conference 2019 Announced

Flow Science, Inc. will hold its FLOW-3D European Users Conference in Milan, Italy on June 3-5 at the Sheraton Diana Majestic. The conference is co-hosted by XC Engineering, the official distributor of FLOW-3D products in Italy and France.

We Solve the World's Toughest CFD Problems

This article explores the science behind FLOW-3D’s accuracy, comprehensive physics and numerical options that combined allow our customers to solve the most challenging free-surface flow problems.


FLOW-3D is an accurate, fast, proven CFD software that solves the toughest free-surface flow problems. A pioneer in the CFD industry, and a trusted leader, FLOW-3D is a highly-efficient, comprehensive solution for free-surface flow problems with human-centric support.

Road Trips and OOP Concepts

"I was broken down midway between New Mexico and New Jersey, waiting for a tow truck, when I received an email from my computer science program at NMSU about the Flow Science software engineering internship..." In our latest blog post, Danya Alrawi tells us about her experience as an intern with Flow Science's GUI group.

How to Reference FLOW-3D Products

The following is a guide for citing FLOW-3D products and publications. Authors of academic papers and other shareable works may use these formats or adapt them to the requirements of their publishing organization as necessary.

Hydraulic Jump in a Trench Type Pump Sump

Hydraulic jumps are a flow phenomenon familiar to people working with open channel applications. Wikipedia defines a hydraulic jump as “a condition where open channel flow abruptly transforms from super- to sub-critical.”

Bugs and Baffles

Read Colton Paul's blog about how he got into the flow during his internship.

Angles of Inclination

In her intern blog, Allyce Jackman discusses applying her Mech Eng degree to CFD.

Chemically Reacting Tanks -- Skipped, No-index

Metal Casting and Mountain Climbing

In his blog, Flow Science intern Ajit D’Brass shares his experiences learning FLOW-3D CAST, developing metal casting simulations, and adjusting to the climate and elevation of New Mexico’s high desert, or as he describes it, "high science in the high desert."

Air Entrainment Analysis

This webinar focuses on how to simulate air entrainment processes in FLOW-3D. This includes details into the theory behind our air entrainment and drift-flux models and a demonstration of how to set up a basic air entrainment simulation in FLOW-3D. We finish up by discussing best practices and approaches for these types of simulations.

Mitigating Total Dissolved Gas at Boundary Dam

The Boundary Dam is located on the Pend Oreille River in northeastern Washington. The project consists of a 340 ft. high concrete arch dam, seven low level sluiceway outlets, two high level overflow spillways (Spillway 1 and Spillway 2), and an approximately 1,003 MW authorized capacity powerhouse.

FLOW-3D (x) Banner NAFEMS

Optimization of a vortex chamber with FLOW-3D (x) Predicting fluid behavior when comparing design alternatives for a hydraulic structure is always a difficult task. Small modifications to a design can drive the system to dramatically better or worse performance. This example of an optimized vortex chamber illustrates how FLOW-3D (x) can be applied to address […]

Exploring Additive Manufacturing and Microfluidics

Ruendy Castillo writes about his experiences as a Flow Science Summer Intern. Ruendy is back at the University of New Mexico pursuing a degree in civil engineering.

CFD, C++ and Soccer

Lizeth Anaya writes about her experience at Flow Science as a summer intern. Lizeth recently graduated from Española Valley High School with a 4.0 GPA and has just begun her first semester at New Mexico Institute of Mining and Technology.

Complex Culvert Hydraulics -- Skipped, No-index

Aeration Tank Modeling -- Skipped, No-index

Flow Science a 2018 Flying 40 Recipient

For the third year in a row, Flow Science was named one of New Mexico Technology’s Flying 40. The New Mexico Technology Flying 40 awards annually recognize the 40 fastest-growing technology companies headquartered in New Mexico.

Density Flows and Heat Transfer -- Skipped, No-index

Combined Sewer Overflow

A typical combined sewer system collects stormwater runoff, domestic and industrial waste into a single pipe for transport. In this blog, I will discuss how FLOW-3D can be used to design or modify complex CSO systems.

Modeling Fishway Passages -- Skipped, No-index

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This site uses cookies - small text files that are placed on your machine to help the site provide a better user experience. In general, cookies are used to retain user preferences, store information for things like shopping carts, and provide anonymised tracking data to third party applications like Google Analytics. As a rule, cookies will make your browsing experience better. However, you may prefer to disable cookies on this site and on others. The most effective way to do this is to disable cookies in your browser. We suggest consulting the Help section of your browser or taking a look at the About Cookies website which offers guidance for all modern browsers.

Flow Science Recognized as New Mexico Family-Friendly Workplace

Flow Science again this year earned gold distinction for its workplace policies by Family Friendly New Mexico, a statewide project developed to recognize companies that have adopted family-friendly policies.

Sludge Settling Model

Settling is the first stage for sewage sludge treatment followed by digestion and disposal. In FLOW-3D v12.0, a sludge settling model has been developed to simulate sludge settlement in septic tanks, clarifiers and other sewage treatment equipment.

Additive Manufacturing: Continued -- Skipped, No-index

Sand Casting Workspace -- Skipped, No-index

Optimizing Design Performance with Baffle Placement

Optimizing design performance with baffles in order to dampen sloshing in liquid storage tanks was the optimization goal of this FLOW-3D (x) case study.

Characterizing Contact Tank Performance

In this FLOW-3D(x) case study, the performance goal is to characterize the performance of a chlorine disinfecting contact tank in an activated sludge process with varying bacteria loads.

Calibrating Simulation Parameters

The goal of this FLOW-3D(x) calibration study was to investigate the impact of various numerical parameters on the simulation of air entrainment on a stepped spillway.

Optimization of a Tilt Pour Casting

In this FLOW-3D(x) case study, the optimization goal is to optimize a tilt pour casting of a combustion engine piston to minimize air entrainment.

2018 FLOW-3D European Users Conference Speakers Announced

Flow Science, Inc. has announced the speakers for its 2018 FLOW-3D European Users Conference, which will be held at Le Méridien Stuttgart Hotel in Stuttgart, Germany on May 14 – 16, 2018.

Piano Key Weir Discharge Analysis -- Skipped, No-index

Modeling Gas-liquid Flows in Water Treatment Plants

Ozone disinfection is a process in water treatment plants for removing bacteria/viruses from the infected water, reducing the concentration of iron, manganese, and sulfur, and reducing taste and odor problems. This blog will discuss FLOW-3D’s new gas mass dissolution model, which helps our users better understand the behavior of the ozone-water mixture in water treatment plants.

Two-fluid, Two-temperature Model

Spacecraft and automotive fuel tanks and certain microfluidic devices require accurate modeling of liquid and gas phases for safe and efficient operations. In addition to the presence of a fluid interface in such systems, the physics of heat transfer and phase change also need to be accurately captured. How is that for complexity! In order to simulate such complex scenarios, a two-temperature, two-fluid model has been introduced in FLOW-3D v12.0.

Overview of Free Surface Modeling Setup -- Skipped, No-index

Announcing the 2018 FLOW-3D Americas Users Conference -- Skipped, No-index

Coastal Applications -- Skipped, No-index

Steady-state Accelerator for Free Surface Flows

Computational efficiency is at the core of FLOW-3D’s treatment of free surface flows. In this blog, with the help of a case study contributed by Dr. C.W. “Tony Hirt”, I will discuss the performance gains obtained by using FLOW-3D’s new steady-state accelerator for free surface flows.

ALL NEW FLOW-3D CAST v5.0 Released

Flow Science has announced a major release of their metal casting simulation software, FLOW-3D CAST version 5.0. New tools for predicting casting defects provide insights that shorten design cycles and reduce cost.

Liquid Metal 3D Printing

In this article about the simulation of liquid metal 3D printing, we will discuss a novel approach to additive manufacturing of 3D metal structures.

Immersed Boundary Method

A technique for approximating the advection term based on the ghost-cell immersed boundary method (Mittal et al. 2008) has been developed for FLOW-3D v12.0. The immersed boundary method technique provides more accurate pressure and force predictions near walls.

Immersed Boundary Method

The accurate prediction of forces and energy losses is crucial in the success of modeling many engineering problems such as discharge from an orifice plate, flow past an obstacle and flow in a sudden contraction pipe. The upcoming release of FLOW-3D v12.0, features a new numerical option, called the Immersed Boundary Method that accurately predicts flows for such problems.

Sand Core Making

This article illustrates how simulation helps optimize the design of core boxes and establishes robust process conditions for shooting, gassing and curing of organic and inorganic binder systems for cold and hot core boxes.

Non-Newtonian Ink Additive Manufacturing

Non-Newtonian ink printing is the future of additive manufacturing. It does not require added heat, instead relying on a pump to eject any number of materials with thick consistencies onto a build platform. However, like any other 3D printing method there is an issue when multiple inks are used for the same product.

Optofluidics: Modeling L2 lenses

Optofluidics refers to the technology that combines optics and microfluidics. This blog, will describe a FLOW-3D validation case study on dynamically configurable lenses, specifically L2 lenses.

Reduce Your Stress by Following These CFD Best Practices

Have you ever invested a significant amount of time generating CAD, meticulously setting up your mesh, defining initial and boundary conditions, and configuring your post-processing instructions only to find your stomach doing a backflip, a moment after you hit the ‘run’ button? CFD best practices are intended to not only help you reduce stress, but also run better simulations!

Optimization of Magnetic Blood Cleansing Microdevices

A novel FLOW-3D model for predicting and optimizing the process of magnetic bead separation from blood in a multiphase continuous-flow microdevice.


FLOW-3D can be accurately used to model acoustophoresis processes to capture the forces acting on particles, directly as a result of flow dynamics, instead of using approximate analytical solutions.

High Performance Computing with FLOW-3D CLOUD

With the increasing use of simulation software for solving complex problems, enabling faster design cycles, while maintaining the accuracy of the solution, is critical. At Flow Science, we understand the importance of providing accurate and validated solutions in shorter durations. To accomplish this we offer a high performance computing version of FLOW-3D called FLOW-3D Cloud.

Marine, Maritime and Coastal Applications -- Skipped, No-index

Cooling and Feeding System Design

In FLOW-3D CAST v5.0, two new tools have been developed to help casters design the cooling and feeding systems for defect-free castings: predictions of the last places to freeze and the calculation of the thermal modulus.

Additive Manufacturing & Welding Bibliography

Learn more about how FLOW-3D AM can be used to successfully simulate the processes found in Additive Manufacturing, Laser Welding, and other welding technologies.


FLOW-3D is used to simulate the hydrodynamics involved in the formation of microfluidic lenses such as the L2 (Liquid core-liquid cladding) lens.

Micro/Bio/Nano Fluidics

Micro, bio and nano fluidics can be easily and accurately simulated with FLOW-3D’s free surface and multi-fluid modeling capabilities.

Droplet Based Microfluidics

FLOW-3D has been used to study acoustically induced inkjets, piezo inkjets, thermal bubble inkjets and many other types.

Heat Transfer Coefficients for Die Spray Cooling

A new, simpler way to calculate heat transfer coefficients for the die spray cooling model has been developed in FLOW-3D CAST v5.0, which is based on known or easy-to-obtain spray medium properties. In this blog, I will talk about the new HTC calculation method followed by an example and a validation.

Continuous Flow Microfluidics

Some of the processes or devices that have been successfully simulated using FLOW-3D are Joule heating, liquid gating, microfluidic circuits, electro-osmotic valves, particle focusing, sorting and separation, point-of-care (POC) capillary flow devices and patterned surface devices.

Digital Microfluidics

Digital microfluidics is a field of microfluidics where electrowetting is used to control and manipulate discrete fluid droplets.

Phase Change

FLOW-3D‘s phase change model is a powerful tool for phase change microfluidics applications by accurately predicting the formation and interactions of vapor bubbles and the surrounding liquid – the bubbles can respond dynamically to liquid motion, and can grow or shrink depending on the temperature and pressure of their surroundings.

Cell Behavior

FLOW-3D can help researchers in devising newer and better gradient generators as shown in the examples below.

Laser Welding and Additive Manufacturing -- Skipped, No-index

Global Conditions for Active Simulation Control

In the first blog in the FLOW-3D CAST v5.0 development series, I will discuss the implementation of Global Conditions for Active Simulation Control. Active Simulation Control was first introduced in FLOW-3D v11.1 and FLOW-3D CAST v4.1 to give users greater control over their simulations in terms of autonomous triggering of actions when appropriate conditions are met during the simulation run.

Continuous Inkjet Printing

In this blog, I will discuss the physics behind continuous inkjet printing, followed by the FLOW-3D simulation studies conducted by Ioannis H. Karampelas, CFD Engineer at Flow Science. Further advancing his work, I ascribe randomness to the droplet generation process, inspired by the application of inkjet in the OLED printing industry, and illustrate the variation in the resulting droplets.

Speakers Announced for the 17th FLOW-3D European Users Conference -- Skipped, No-index

Configurable Simulation Monitor

FLOW-3D CAST 's Configurable Simulation Monitor expands on the capabilities of the history data plotting tool from previous versions. Now, users will able to add and monitor any history data in the simulation through the runtime plots.

Computational Analysis of Drop Formation and Detachment

Rapid, repeated, precise creation and deposition of droplets are of great importance to a variety of new and old industrial applications.

Microfluidic Palette – A Gradient Generator

Continuing our work with microfluidics modeling, simulating and validating gradient generation devices is our latest undertaking at Flow Science. Diffusive based gradients are an integral part of many complex biological processes.

The Optimal Solution: CAESES and FLOW-3D

Optimization is an integral part of any design process that incorporates simulation.

Flow Science Earns Recognition as New Mexico Family-Friendly Workplace

Flow Science earned distinction from Family Friendly New Mexico, a statewide project developed to recognize companies that have family-friendly workplaces.


Designed for running extremely large simulations, parametric studies or design of experiments (DOE), FLOW-3D CLOUD lets you expand your simulation capabilities without worrying about acquiring and maintaining a cluster.

Microfluidics Particle Sorting Using Gravity

Microfluidic particle sorting has applications in diagnostics, chemical and biological analyses, food and chemical processing as well as environmental assessment. In a previous blog I talked about microfluidics particle sorting using hydrodynamics. Building on the same topic, I will discuss another method of micro particle sorting using gravity.

Runner System Optimization

Design optimization is a mathematical technique that can be used, together with computational fluid dynamics, to identify the best design to achieve one or more desired objectives, while taking into account a spectrum of design parameters and constraints. Optimization has become more and more popular in recent years as quality requirements increase and computational resources become faster and more-powerful, allowing for iterative runs.

Flow Science Announces 2017 FLOW-3D Americas Users Conference

Flow Science, Inc. has announced that it will hold its 2017 FLOW-3D Americas Users Conference in Santa Fe, NM on September 20-21 at the Hotel Santa Fe.

Advanced Microfluidic Flow Modeling -- Skipped, No-index

Microfluidics Particle Sorting Using Hydrodynamics

Microfluidic particle sorting has applications in diagnostics, chemical and biological analyses, food and chemical processing as well as environmental assessment. This blog will discuss how FLOW-3D can simulate the physics of particle sorting techniques.

Water Resources - A comprehensive review -- Skipped, No-index

SFCC Hosts Julia Robinson Mathematics Festival

Santa Fe Community College is partnering with STEM Santa Fe and Math Circles Collaborative of New Mexico to host New Mexico’s first Julia Robinson Mathematics Festival.

Spillway Hydraulics Assessments

BC Hydro, a public electric utility in British Columbia, uses FLOW-3D to investigate complex hydraulics issues at several existing dams and to assist in the design and optimization of proposed facilities.

Mixing in Microchannels - Design Optimization

Mixing fluids can be very important in the design of miniaturized chemical and biochemical analysis systems. In a previous blog, I discussed the challenges that arise because of the laminar flow regime and how one might try to overcome the challenges by modifying geometry to induce mixing. In this blog, I will discuss our work on further optimizing the microchannel geometry using the design optimization software, CAESES®, from Friendship Systems GmbH.

A Tour of Interactive Geometry Creation

The last in our series of blogs on FLOW-3D v11.2’s new developments is this discussion of the new tool for interactive geometry creation. This post will take you on a quick tour of a few applications and benefits of this tool.

More on Mooring Lines

Continuing our series of posts dedicated to FLOW-3D v11.2’s new developments, and moving on from the world of particles, I will talk today about the new capabilities that have been added to our mooring lines model. In FLOW-3D v11.2, new features include predicting breaking of lines, and the ability to simulate the free end dynamics of mooring lines.

17th FLOW-3D European Users Conference Announced -- Skipped, No-index

Gas Particles and Microbubble Mixing

Mixing different fluids with potentially different properties remains one of the most important and potentially costly industrial processes. In this article, I will complete our presentation of the newly-redesigned particle model in FLOW-3D v11.2 and take a fresh look into one of the most common and essential industrial processes: mixing.

Flow Science Releases FLOW-3D v11.2

Flow Science announced the release of FLOW-3D v11.2. This release includes major new features, significant advances in solver performance as well as user conveniences and performance improvements.

Laser Metal Deposition and Fluid Particles

Continuing with the blog series featuring new developments in FLOW-3D v11.2, I will focus in this post on the capabilities of fluid particles, one of the new particle classes in the particles model. Fluid particles directly inherit fluid properties, including evaporation and solidification. There can be a variety of cases where fluid particles can be applied: from a relatively simple rainfall modeling to complicated Selective Laser Melting (SLM) modeling.

Mass Particles and Acoustophoretics

FLOW-3D v11.2 is all set to be released in a few weeks with many improvements to existing models and new developments. In anticipation of this release, we are turning the focus of our blog series to new developments coming in this release, like the particle model, wave absorbing components, mooring lines and interactive geometry.

Prediction of Shrinkage Defects During Investment Casting Process

Mold filling and solidification simulations of the investment casting process were carried out using FLOW-3D CAST. Parametric studies have been conducted to study the effect of casting parameters on the casting process.

Dynamic Droplet Model for Two-Component Flows

There are many two-fluid mixtures of practical interest. For example, mixtures of air and water or oil and water occur frequently in environmental and industrial processes. FLOW-3D offers the capability for modeling mixtures of two fluids and the relative motion of the two components arising from buoyancy and viscous forces.

Thermocapillary Actuation

Microfluidic devices like lab-on-a-chip involve parallel and automated routing, mixing and reacting of a multitude of liquid samples. One way of performing these actions is using thermocapillary actuation. Thermocapillary actuation does not require any external mechanical forces, and therefore is a cleaner and more cost-effective way of transporting fluid samples.

Water Resource Recovery Facilities -- Skipped, No-index


Nucleation is widely studied in many scientific and technological processes; however this blog is inspired by a relatively new field of application, phase-diagram-on-a-chip. Generally speaking, phase diagrams are graphs used in the field of physical chemistry to show various phases of a substance with changing conditions of pressure, temperature, etc. When a phase diagram is directly generated on a micro-chip (as opposed to the traditional way of drawing it on a page from experimental data) it is called a phase-diagram-on-a-chip.

Friendship Systems and Flow Science Form Partnership -- Skipped, No-index

Modeling Open Surface Microfluidics

In a recent paper from researchers from the University at Buffalo and University of Grenoble, it was shown how microgrooves can potentially enhance the capillary effect. Based on the results of this paper, I will discuss a case study of the spontaneous capillary flow of fluids inside a narrow V- groove microchannel surmounted by parallel plates using FLOW-3D. Large fluid velocities can be obtained, even with viscous fluids such as whole blood for the design of POC systems to monitor blood flow, if certain conditions for the onset of capillary flow are satisfied.

Micromixing Using Curved Microchannels

Mixing fluids can be very important in the design of miniaturized chemical and biochemical analysis systems. However, the mixing of fluids at the micro-scale is challenging because of an inherent lack of any mechanism to induce the mixing. Turbulence is a good natural way to cause mixing, but microfluidic processes are laminar in nature. In this blog, I will talk about the challenges that arise because of the laminar flow regime and ways to overcome those challenges when designing micromixing devices.

Press Releases

Read Flow Science’s press releases, featuring the latest developments in its computational fluid dynamics software (CFD) products based on its flagship software, FLOW-3D, events and business updates.

Microfluidic Flow Modeling -- Skipped, No-index


FLOW-3D products are offered exclusively through Flow Science’s headquarters in the US and through our network of subsidiaries and international distributors.

Trade Office Sees More Success -- Skipped, No-index

Laser Powder Bed Case Study

Laser-powder bed fusion additive manufacturing involves complex physical processes. Particularly, the absorbed laser beam energy melts the particles and forms a molten pool where a strong fluid flow occurs driven primarily by surface tension gradient.

Die Spray Cooling

The Die Spray Cooling model simulates the spatial variation in the spray cooling to accurately predict the temperature distribution in the die in thermal die cycling simulations.

Venture Acceleration Fund Boosted By Full Award Payback

Structured as a zero-interest loan with payback only required when a company meets certain revenue goals, is acquired or moves out of state, the VAF has just received its second payback from Flow Science, Inc.

Capillary Flows

Capillary flows are commonly encountered in microfluidic devices. This page covers some specific applications for FLOW-3D in the analysis of such capillary flows: filling, absorption and switching.

New Die Spray Cooling Model

In this last blog on FLOW-3D CAST v4.2’s developments, I discuss the new Die Spray Cooling Model for thermal die cycling simulations. The new model provides accurate temperature distribution on the die surfaces with reliable and realistic input parameters, which helps engineers to better design and optimize the cooling process to eliminate hot spots. A sample thermal die cycling simulation demonstrates the capability of the new model, and the importance of explicitly simulating the die spraying process.

HPDC Process-oriented Workspaces

High Pressure Die Casting (HPDC) simulations are typically very complex as they include almost all of the possible physical processes including heat transfer, melting/solidification, air entrainment, surface defect tracking, and cavitation. As a result, setting up casting simulations can be quite time intensive and error prone. HPDC Process-oriented Workspaces have been added to FLOW-3D CAST v4.2 to help users create simulations quickly and free of errors.

Flow Science Releases FLOW-3D CAST v4.2 -- Skipped, No-index

WYSIWYN - What You See Is What You Need

Later this month, our metal casting users will be WYN-ing with the release of FLOW-3D CAST v4.2. This new release features a streamlined user interface designed with a focus on WYSIWYN – What You See Is What You Need. The FLOW-3D CAST v4.2 interface will make simulation setup more efficient and error free by providing a consistent layout and a flat design that shows users the most important simulation information on the top level.

Non-Inertial Reference Frame Motion

Adapting non-inertial reference frame model results to enable visualization from a stationary frame of reference is a nifty new feature coming in the upcoming releases of FlowSight™ for FLOW-3D CAST v4.2 and FLOW-3D v11.2. This brief note describes this feature and gives a couple examples.

2016 Americas Users Conference Announced -- Skipped, No-index

FLOW-3D Blog

Subscribe to the FLOW-3D blog to learn about upcoming CFD software developments, novel applications and featured customer case studies.

16th FLOW-3D European Users Conference Speakers -- Skipped, No-index


The particle model in FLOW-3D has undergone a major transformation to expand its capabilities. In the current model, particles are grouped into classes based on their primary functionality.

Microfluidic Circuit - Pneumatic Latching Valve

In this final post in the series of Flow Science’s 35th anniversary simulation contest, I will talk about a case study simulating a part of a microfluidic circuit – pneumatic latching valve. These devices are a relatively new industry application that Flow Science is exploring, in the context of a broader exploration of the use of CFD in microfluidics applications, and results have been very encouraging.

Flow Science Expands into Latin America

Flow Science, Inc. announced that it has formed a new subsidiary, Flow Science Latin America SAS, to sell and support Flow Science’s suite of computational fluid dynamics software products throughout Central and South America.

Simulating Pelton Turbines

Pelton turbines are used for electricity generation in hydraulic power plants. They are suitable for operation when water energy is available at high head and low flow rate. In a Pelton turbine, the energy extracted from the kinetic energy of the water is used for the rotation of the impeller.

Modeling Environmental Flows -- Skipped, No-index

Floating Structures

Floating structures on an ocean surface, restrained by mooring ropes, are a common sight in the oil and gas industry. The problem of understanding the dynamic response of a floating structure becomes challenging due to the complex dynamics of the system. In this article, I will talk about the dynamic response of a floating structure made of 3 elements hinged together, followed by a presentation of FLOW-3D simulation results.

Turbulent Dispersion Modeling of Environmental Discharges

Environmental discharges and outfall structures have been traditionally designed by means of complex, cost-intensive and time-consuming experimental studies.

16th FLOW-3D European Users Conference Announced -- Skipped, No-index

Flow Science Releases FLOW-3D/MP v6.1 -- Skipped, No-index

Cavitation Model Improvements

Cavitation is the evolution of vapor and/or gas bubbles within liquid in the regions of low pressure in the flow, or due to heating that raises the vapor saturation pressure. The sudden appearance and subsequent collapse of bubbles may cause large oscillations of pressure within incompressible fluid that in turn result in severe mechanical damage to the surrounding structures.

Flow Science Releases FLOW-3D CAST v4.1 -- Skipped, No-index

New Boundary Conditions

For numerical modeling of river flows, typically water elevation is required at the upstream boundary. Yet water elevation in natural environmental systems is often unknown and has to be estimated. Improper elevation estimation, however, can generate nonphysical results.

Flow Science Releases FLOW-3D v11.1 -- Skipped, No-index

Raster Data Interface

FLOW-3D allows users to import solids in STL (StereoLithography) format to represent complex geometries, regardless of the application – micro fluids, metal casting, water and environmental, aerospace, etc. In the upcoming release of FLOW-3D, we have adopted an industry norm for terrain import: the file format known as the ESRI ASCII raster format.

P-Q Squared Analysis

P-Q squared analysis is a standard procedure used to optimally match the target gate velocity to the capabilities of the HPDC (High Performance Die Casting) machine’s plunger hydraulic system. Desired fill time and an optimum gate design can be attained by performing P-Q squared analysis, which in turn, maximizes the efficiency of the HPDC system.

Validation of Sloshing Simulations in Narrow Tanks

This work validates FLOW-3D against a sloshing problem in a sealed narrow span rectangular tank, subjected to roll motion at periods close to or equal to the tank’s internal wave resonance period.

Squeeze Pins

In order to predict these real-world scenarios, a squeeze pin model has been developed in FLOW-3D CAST v4.1 to help design and optimize the squeeze pin process parameters.

Solid Propellant Combustion Modeling

Solid fuel combustion is a traditional method of extracting energy from solid objects. However, an important relatively new application of solid fuel combustion is in rocket propulsion. The development of the new Combustible objects model in FLOW-3D v11.1 was motivated by solid propellant combustion in rockets.

Thermal Die Cycling Model

Thermal die cycling is a standard process die casting facilities use to get their die up to temperature for full production. Think about showing up to work in the morning, mid-winter: your machines are cold! Typically someone will fire the die to get the machines warmed up and then go through a series of “dry shots."

Mooring Lines Model and Wave Absorbing Layer

While the Mooring Lines model and the Wave Absorbing layer are two separate developments in FLOW-3D v11.1, I am going to talk about both in this post because users will often use them together in simulations. Although these developments can be used hand in hand, completely independent use of each is also possible.

Improved Runtime

Developers at Flow Science are constantly working to improve the performance of our solver. We want to provide our users the same experience, i.e., accuracy and ease of use of FLOW-3D and FLOW-3D CAST, but with shorter runtimes. In the upcoming releases - FLOW-3D v11.1 andFLOW-3D CAST v4.1 - the results are the same, but the computational time is significantly reduced.

Speakers Announced for the 2015 FLOW-3D Americas Users Conferences -- Skipped, No-index

Active Simulation Control

Many real-world processes involve actions that are triggered when a certain design stage or any prescribed objective or limitation is reached, independent of real timing. Active Simulation Control is a powerful new feature in the upcoming release of FLOW-3D v11.1 that allows users to decide the course of a simulation depending on the design stage of the process.

Viscoelastic Flow

FLOW-3D includes viscoelastic flow models that predict the behavior of material that behave both like liquids and solids, depending on the local strain and strain rate.

Active Simulation Control

A feature in FLOW-3D and FLOW-3D CAST called Active Simulation Control provides users with complex logical triggers to define the necessary “what if – then do this” control over their simulations.

FLOW-3D Workshop Licensing -- Skipped, No-index

Investigation of Mould Leakages in a Gravity Casting

Mould design is a complex undertaking that must consider not only fluid dynamics and metal solidification patterns, but problems that may arise from the mould itself and how it reacts to stresses from heat transfer. In this case study, CM Taricco, a mould maker company based in Italy, discusses how they solved the problem of metal leakages at the bottom of one of their new moulds.

Flow Science Extends Association with Dazztech Solutions -- Skipped, No-index

Flow Science Forms New Association with J-ROM (Israel) -- Skipped, No-index

Automotive Presentations -- Skipped, No-index

Flow Science Extends Association with Flow Science Deutschland GMBH -- Skipped, No-index

License Server Change Request -- Skipped, No-index

Modeling Spillways, Stilling Basins and Hydraulic Controls -- Skipped, No-index

Speakers Announced for the 15th FLOW-3D European Users Conference -- Skipped, No-index

Fish Ladder Design

In this study, FLOW-3D played in instrumental role in the design of an innovative fish baffle for use within fish ladders used to regain lost riverine fish habitats


FLOW-3D’s cavitation model has been successfully used to simulate thermal bubble jets and MEMS devices. FLOW-3D offers the option of “active” or “passive” models.

Automotive Bibliography

Learn more about how  FLOW-3D can be used to successfully simulate applications for the Automotive Industry in our Automotive Bibliography.

Flow Science Announces Its 2015 Americas Users Conferences -- Skipped, No-index

Flow Science Forms New Association with Design Through Acceleration -- Skipped, No-index

Municipal and Wastewater Hydraulics Modeling -- Skipped, No-index

Increasing Productivity by Reducing Ejection Times

In high pressure die casting, simulation software is used to help design better gating systems to feed the metal into the casting, improve the timing of the shot sleeve tip to prevent air entrainment due to turbulence, and identify the most effective locations for overflows, among other things. In this article, we will look at how to reduce the time before a part can be ejected from the die in order to reduce the process time.

Mooring Lines

FLOW-3D's mooring line model considers gravity, buoyancy, fluid drag and tension force on the mooring lines. Full 3D dynamics of mooring lines are calculated as well as their dynamic interactions with tethered objects. The lines can be taut or slack, and their instantaneous shape is computed.

Indianapolis Storm-Water System

Sewer systems don’t seem very exciting unless they serve as action-movie get-away routes. Most likely you don’t even think about them until torrential rain brings water up to curb-level.

Suggestion Drop Box -- Skipped, No-index


Flow Science Announces New Consultancy Agreement with Minerva Dynamics -- Skipped, No-index

15th FLOW-3D European Users Conference Announced

Flow Science, Inc. has announced that it will hold its 15th annual FLOW-3D European Users Conference on June 2-3, 2015 in Nice, France at the Hotel Westminster. A half-day of FlowSight™ training will be offered the afternoon of June 1.

Hydraulic Boundary Conditions

Practicing hydraulic engineers typically employ rating curves that relate fluid elevation and volume flow rate at selected cross-sections of a river. To provide such data to FLOW-3D users, new rating-curve boundary conditions have recently been developed, making it easier to model many types of flows.

Validation of a 3D Dam Breaking Problem

A 3D dam breaking with obstacle configuration was chosen as one of our validation cases in order to assess FLOW-3D’s performance for the simulation of free-surface flows.

Flow Science Releases FLOW-3D/MP v6.0

Flow Science has released FLOW-3D/MP v6.0, the high-performance computing version of its flagship CFD software. FLOW-3D/MP v6 is fully synched with the FLOW-3D's latest developments.

Coastal and Maritime Presentations

Download coastal and marine presentations

Speakers Announced for the 2014 FLOW-3D Americas Users Conference

Flow Science has announced the speakers for its 2014 FLOW-3D Americas Users Conference, to be held on September 9-10 at the Courtyard Marriott Downtown Toronto, in Toronto, ON, Canada.

Aerial Landslide Generated Wave Simulations

With the continuing advancements of computer hardware and CFD software, it is now possible to practically simulate aerial landslide generated waves using CFD.

Sales Contact Confirmation -- Skipped, No-index

Flow Science Receives Venture Acceleration Funding -- Skipped, No-index


FLOW-3D offers a comprehensive turbulence modeling suite for fully 3-D flows, 2-D depth-averaged (shallow water) flows, and hybrid 3-D/2-D depth-averaged flows.

Contact Sales

Whether you have a short-term project, want to understand how the FLOW-3D family of products can be applied to your industrial application or research project, or want to take your current use of the software to the next level with FLOW-3D CLOUD , our team of experienced CFD engineers is ready to help you solve the toughest CFD problems..

FLOW-3D CAST v4.0 Press Release

Flow Science, Inc. announces the availability of a new release of FLOW-3D CAST, version 4. A major release, FLOW-3D CAST v4 provides users many new simulation tools to improve metal castings.

Advanced CFD Simulations in Biotechnology -- Skipped, No-index

St. Francis Dam Break Analysis -- Skipped, No-index

General Applications Bibliography

Learn more about how FLOW-3D can be used to successfully simulate problems that involve complex multiphysics in our General Applications Bibliography.

Terms of Use

Making useful information available to our customers and web site visitors without infringing on their privacy is very important to us. Flow Science, Inc. safeguards the security of the data you send us with physical, electronic and management procedures. For more information about our privacy practices, view our full Privacy Policy.

Privacy Policy

The purpose of this Privacy Policy is to inform all individuals from whom Personal Data is collected how FSI collects and uses such Personal Data and how you can control its use.

FLOW-3D Version 11 Press Release -- Skipped, No-index

Advances in Nanotechnology

Research in Professor Furlani's group involves modeling and simulation towards the development of novel processes and devices.

14th FLOW-3D European Users Conference Speakers Announced Press Release -- Skipped, No-index

Granular Media

Many types of granular media are encountered in processing and manufacturing industries. Because of its unusual properties, granular material can often pose difficult problems for engineers seeking to transfer, mix or otherwise manipulate it for useful purposes.

Water & Environmental Bibliography

Learn more about how FLOW-3D can be used to successfully simulate applications for the Water & Environmental Industry in our Water & Environmental Bibliography.

Microfluidics Bibliography

Learn more about how FLOW-3D can be used to successfully simulate microfluidic processes and devices in our Microfluidics Bibliography.

Metal Casting Bibliography

Learn more about how FLOW-3D CAST can be used to successfully simulate applications for the Metal Casting Industry in our Metal Casting Bibliography.

Coastal & Maritime Bibliography

Learn more about how FLOW-3D can be used to successfully simulate Coastal & Maritime applications in our Coastal & Maritime Bibliography.

Coating Bibliography

Learn more about how FLOW-3D can be used to successfully simulate coating processes in our Coating Bibliography.

Aerospace Bibliography

Learn more about how FLOW-3D can be used to successfully simulate applications for the Aerospace Industry in our Aerospace Bibliography.

Chemistry-based Solidification Model

FLOW-3D CAST v5.1’s new, state-of-the art, chemistry-based solidification model advances the industry into the next frontier of casting simulation – giving users the ability to predict the strength and integrity of cast parts while reducing scrap and still meeting product safety and performance requirements.

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Microscopic Bubbles Switch Fiber-Optic Circuits

Computer simulation played a critical role in understanding and solving a problem with microscopic bubbles in a revolutionary switch used to switch optical signals in fiber-optic circuits.

Inkjet Printhead Performance

Simulations enable Océ engineers to quickly evaluate the performance of a wide range of possible designs and zero in on the most promising alternatives into which substantial time and expense required for MEMS prototyping is invested.

Kodak Develops New Printhead Design in 1/3rd the Time

Kodak researchers recognized that to meet the time constraints of the project, they needed both very accurate simulation software and a systematic method of optimizing their design. Using FLOW-3D and D-optimal designed experiments (DOE), Kodak researchers accomplished the task in only three years.

Earthrace: Speed, Fuel Efficiency and Safety

Earthrace, which aims to demonstrate the viability of biofuel to to power a ship around the world, found FLOW-3D invaluable for simulating and optimizing their design performance.

Wave Impact on Offshore Structures

For structures like semi-submersibles and tension leg platforms, the prediction of the minimum air gap and the probability of deck impact events are challenging.

Interaction Between Waves and Breakwaters

Until recently, the complex aspects of breakwater behavior were considered too challenging for detailed numerical simulations.

Wave Forces on Coastal Bridges

To prevent future hurricane damage to coastal bridges, the magnitude of wave loads on bridge superstructures must be determined with reasonable accuracy.

Debris Transport in a Nuclear Reactor Containment Building

CFD has proved to be valuable in identifying containment pool water level changes, flow patterns, and plant design modifications.

Evaluation of the Wind Effects on the Iron-Ore Stock Pile

The effect of wind on open aggregate storage piles is becoming a growing environmental problem around the world.

Comparing HVAC System Designs

The simulations provided a detailed comparison and supplied Tecsult's HVAC system engineers with valuable data to support their design choice.

Architects Achieve LEED Certification in Sustainable Buildings

FLOW-3D has helped to earn the credit "IEQ- Credit 2 – Increased Ventilation" in an office building in Bogotá (Colombia).

Grit Chamber Modeling

A continuous input of suspended sediment at the chamber inlet tunnel is being investigated with the help of FLOW-3D for different pumping rates.

Hydrodynamic Screws

The use of small-scale hydro power is becoming more interesting as a way to control the increasing costs of energy.

Landslide-Induced Wave Hazard

The Moving Objects model in FLOW-3D was used to simulate the landslide and the VOF model was used to simulate wave generation.

Wastewater Treatment Plant

When Earth Tech designed and built the 4th in a series of 7 large wastewater treatment plants, FLOW-3D was used to optimize the design of critical components in the treatment stream.

Improving Clarifier Performance

When NEFCO engineers sought to refine their procedures used to design their Density Current Baffle Systems, they developed a comprehensive analysis approach based on experience, the results of field studies and state-of-the-art modeling computer modeling.

CFD + Physical Modeling Results

For over a decade, Manitoba Hydro has tackled the complexity of hydroelectric plant design with the power of FLOW-3D.

Commercial Aquaculture Systems

Many factors influence marine aquaculture: tidal fluctuations, water temperature, food concentration and stocking density, among others.

Sturgeon Navigate Fish Ladder

Using FLOW-3D, AECOM Tecsult inc. was able to improve a fish ladder design that allows sturgeon to successfully navigate the ladder without using physical modeling.

Success Criterion for Fish Passages

With the computed LES results a preliminary discussion between biologists and engineers of the flow conditions inside the fish passes can be started.

Simulating Cross-Bar Block Ramps

This research investigation deals with physical and numerical simulations of a cross-bar block ramp to identify the art of nature flow and to compare this with available analytical guideline solutions.

Design of a Sewer Transition

One of the many technical problems to overcome before construction was the railway entrance at the city center, consisting of a tunnel, which forced a deviation of the main south sewer at Valencia.

Modular Permeable Pavements

This study focuses on modelling and visualizing changes in permeable pavements using FLOW-3D to validate laboratory and on-site experimental results.

São Roque Hydro Power Plant

The São Roque hydroplant project is located in Brazil, in the State of Santa Catarina, on the Canoas River.

Detecting Porosity with the Core Gas Model

One casting defect that has yet to be thoroughly addressed is the common core gas blow defect. The physics of this problem involves a complicated interaction between the metal, core and binder. Failure to solve it can result in high scrap levels. Read about how GM Powertrain and Graham-White Manufacturing Co. addressed core gas defects with FLOW-3D CAST.

Improving High Pressure Die Casting Designs

Littler Diecast was able to demonstrate that they could pinpoint the defects through simulation without previous knowledge of the problems. This impressed the client enough to land them the job.

Realizing Da Vinci's Il Cavallo

In the late 15th century, Leonardo Da Vinci spent 17 years devising a plan to cast a 24-ft. tall bronze horse—the largest equestrian statue in the world—in a single pour.

Integration of CFD Analysis into Die-Cast Process Design

With the goal of compressing die-cast process development time, modeling with FLOW-3D has become an integral part of Shiloh Industries' engineering department.

Aluminum Integral Foam Molding Process

Researchers from the University of Erlangen-Nurember concluded that FLOW-3D CAST is an important instrument to investigate potential weak points in the fabrication of new integral foam parts before their actual production. In that way, a successful filling and blowing agent distribution without cold flow or dead zones can be assured.

Water & Environmental Presentations -- Skipped, No-index

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Authorized Resellers in China

Flow Science China has resellers for the FLOW-3D product family throughout China. Check the list below to find a reseller near you to find out more about how you can acquire FLOW-3D software products.

Flow Focusing

The simulation provided here shows a flow focusing geometry integrated into a microfluidic device

Cooling Channels

FLOW-3D CAST ‘s cooling channel model offers a wide range of features, allowing users to accurately capture the complex behavior of the modern systems, assuring an optimum design and casting properties.

Heat Transfer

The heat transfer model in FLOW-3D and FLOW-3D CAST solves full conjugate heat transfer equations, accounting for heat transfer within and between fluid, solid and void through conduction, convection and radiation.

Water & Environmental Models

FLOW-3D‘s unique strengths in modeling 3D free-surface flows make it a natural platform for advanced water and environmental applications.

Metal Casting Models

FLOW-3D CAST contains a wide variety of physical models specially designed for metal casting. It offers the most accurate solutions to all kinds of metal casting applications and concerns. With it, our customers are constantly improving casting yield and quality, in less time and with lower costs.

Multiphase Flows

FLOW-3D‘s phase change model simulates vaporization and condensation at a liquid/gas interface. It predicts the formation and interactions of vapor bubbles throughout a surrounding liquid.

Supported Platforms

FLOW-3D CAST requires 64-bit CPUs. Intel Xeon, Core i9, or Core i7 processors are recommended. A minimum of 4GB of RAM is recommended per processor core.

Air Entrapment

The air entrapment model in FLOW-3D CAST is used to estimate the amount of entrained air occurring in metal casting systems, such as gravity-poured casting processes.

Hydraulic Energy Losses

FLOW-3D introduced hydraulic energy flow and total hydraulic head as integral values that can be computed with flux baffles, visualized as time series, and analyzed with external tools.

Why FLOW-3D?

FLOW-3D is a powerful modeling tool that gives engineers valuable insight into many physical flow processes. With special capabilities for accurately predicting free-surface flows, FLOW-3D is the ideal CFD software to use in your design phase as well as in improving production processes.

Request a Personalized Demo

Interested in learning more about how you can solve the toughest CFD free surface flow problems with FLOW-3D products? Our CFD Engineers will provide you with a personalized demonstration addressing your specific use case.

Contact Us

Use the form below to request information about our CFD products or if you have a general inquiry. Want to speak to a real live person? Call us at +1 505-982-0088. All inquiries will be answered promptly within business hours. We are open from 8:00 am to 5:00 pm Mountain Time, Monday through Friday except for holidays.


FLOW-3D possesses the capabilities to simulate regular linear and nonlinear propagating surface waves as well as irregular waves.

Thermal Stress Evolution

The addition of the new coupling options between FSI components and TSE solidified fluid regions to FLOW-3D provides a useful tool for evaluating the complex geometries regularly encountered by today’s engineers.

Surface Tension

FLOW-3D's surface tension model accurately predicts all computed surface tension forces, as well as the accuracy of adhesion forces gripping solid surfaces of arbitrary shape.

Sediment Transport Model

FLOW-3D‘s Sediment Transport model can be used to evaluate scour and deposition, where three-dimensional flow components are driving the scouring process.

Salt Dissolution

Salt dissolution in liquid is involved in many CFD applications—from solution mining to food processing to medical applications.

Porous Media

FLOW-3D can simulate both saturated and unsaturated flows within porous media. Saturated porous media flows are for situations where there is a sharp interface between the saturated zone and the unsaturated zone, with a specific capillary pressure present at the interface.

Hybrid Shallow Water/3D Flow

The hybrid shallow water/3D flow model in FLOW-3D is designed to model flow around 3D structures within a ‘shallow water’ environment, such as bridges, drilling rigs at sea and dams in large reservoirs.

Moving Objects

In a FLOW-3D simulation, a general moving object (GMO) is a rigid body with any kind of motion that is either user-prescribed or dynamically coupled with fluid flow. It can have six degrees of freedom or motion constraints such as a fixed axis/point.

Fluid Structure Interaction

FLOW-3D's fluid structure interaction model describes fully-coupled interaction between fluid and solid using a finite element approach to model stresses and deformations in solid components in response to pressure forces from the surrounding fluid, thermal gradients, and specified constraints.

Cast Iron

FLOW-3D CAST ‘s cast iron model describes the solidification of hypo- and hyper-eutectic iron-carbon-silicon alloys. It predicts the formation of graphite, austenite (or gamma-iron) and carbide phases during the eutectic reaction.

Core Gas

The Core Gas model predicts defects for resin-bonded cores both in iron castings and in aluminum castings. It works concurrently with filling and solidification models and computes binder gas generation and flow during and after the casting filling.

Air Entrainment

FLOW-3D‘s air entrainment model allows engineers to predict air entrainment in their designs and make appropriate modifications to ensure they function safely.


Explore a career with Flow Science! Since our founding in 1980 by VOF pioneer Dr. C.W. Hirt, our mission has been to help our customers solve the toughest CFD problems around the world using FLOW-3D products. We are a diverse, creative and dynamic team headquartered in beautiful Santa Fe, New Mexico.

VOF - What's in a Name?

In CFD, a free surface is an interface between a liquid and a gas in which the gas can only apply a pressure on the liquid.

No Loss with FAVOR (TM)

The Fractional Area-Volume Obstacle Representation, FAVOR(TM), method used exclusively in FLOW-3D eliminates zigzag direction changes by smoothly blocking out fractional portions of grid cell faces and volumes.

Free Gridding Saves Time

An example of the free gridding technique used in FLOW-3D should make clear the advantages offered by this approach for CFD analysis.

FAVOR vs. Body-Fitted Coordinates

The simplicity of the fractional area/volume FAVOR™ method for modeling complex geometric regions is very attractive. But, does its accuracy compete with deformed grids like finite-element or body-fitted coordinate methods?

Modeling Techniques

Anyone who has used CFD extensively will have his or her own preferences for what the best numerical methods are to use.

Unconditional Numerical Stability

It is well known that explicit (e.g., forward in time) finite-difference approximations used to solve time-evolution equations are subject to limits on the size of the time increment.

Implicit vs. Explicit Numerical Methods

Numerical solution schemes are often referred to as being explicit or implicit. When a direct computation of the dependent variables can be made in terms of known quantities, the computation is said to be explicit.

Convergence Criteria

FLOW-3D uses the self-corrective procedure as well as an automatic setting of the convergence criteria that adjusts e to whatever is happening during the course of a solution.

What are Artificial and Numerical Viscosities?

Although artificial viscosity was introduced for numerical reasons, it is an elective addition used to modify a physical process so that it can be more easily computed. Artificial viscosity should not be confused with numerical viscosity, which is an unwanted consequence of certain types of numerical approximations.

Relaxation and Convergence Criteria

Numerical methods used to solve the equations for fluid flow and heat transfer most often employ one or more iteration procedures. By their nature, iterative solution methods require a convergence criteria that is used to decide when the iterations can be terminated.

Numerical Instability

In this article, a simple mechanical model is described that leads to an understanding of common numerical instabilities associated with approximations of the Navier-Stokes equations.

Heuristic Analysis

In this article a simple heuristic analysis method is described for investigating the computational stability of such finite-difference equations.

Computational Stability

It is a fact of life that numerical approximations to differential equations may exhibit unstable behavior.

Numerical Issues

Computational modeling involves not only the consideration of a host of physical issues, but also there are many aspects associated with numerical approximations that likewise have to be addressed.

The Incompressibility Assumption

All materials, whether gas, liquid or solid exhibit some change in volume when subjected to a compressive stress.

To Conserve or Not

To maintain the order of an approximation when changing from a uniform to non-uniform grid, it is necessary to abandon conservative formulations. Modified equation forms can be easily derived that preserve the conservation property in uniform grids, and retain the same order of accuracy when grid non-uniformities are introduced.

Grid Overlay Procedure

The Grid Overlay procedure allows users to check the effects of grid refinement or to efficiently compute problems in which the region of interest is progressively decreasing or increasing (e.g., an explosion).

Outflow Boundary Conditions

In many simulations, fluid must flow out one or more boundaries of the computational region. But what constitutes a good boundary condition at such “outflow” boundaries?

Pressure Boundary Conditions

The ability to specify a pressure condition at one or more boundaries of a computational region is an important and useful computational tool.

Reynolds Number

What are the highest and lowest Reynolds number flows that can be accurately computed by a given numerical method?

Physical Phenomena

When using CFD to study a fluid dynamics problem there are numerous details that should be considered in order to ensure useful results.

Lagrangian Particles

Lagrangian particles are an extremely useful computational tool, especially when they are used to track small amounts of material whose dispersion is to be minimized. When particles are used as a discrete model for a continuous medium, however, it must be remembered that they have some limitations.

Turbulence Modeling

The majority of flows in nature are turbulent. This raises the question, is it necessary to represent turbulence in computational models of flow processes?

Free Surface Modeling Methods

An interface between a gas and liquid is often referred to as a free surface. The reason for the “free” designation arises from the large difference in the densities of the gas and liquid, e.g., the ratio of density for water to air is 1000.

Grid Systems

Gridding is the process of subdividing a region to be modeled into a set of small control volumes. Associated with each control volume are one or more values of the dependent flow variables (e.g., velocity, pressure, temperature, etc.)

Rectangular Grids

Most techniques for doing computational fluid dynamics rely on the subdivision of space into a grid of discrete volume elements in which average values of flow variables can be defined.

General CFD

A basic requirement for computational fluid dynamics (CFD) is to have a discretization of space into small elements in which fluid properties such as density, pressure and velocity can be uniquely assigned to each element.

Free Surface Fluid Flow

Many computer programs can solve the partial differential equations describing the dynamics of fluids. Not many programs are capable of including free surfaces in their simulations.

Selecting the Right CFD Software

Software packages for fluid flow and heat transfer analysis come in many forms. The following discussion covers some important items to consider when selecting the right CFD software.


In these FLOW-3D webinars on-demand, our CFD engineers demonstrate FLOW-3D's unique modeling capabilities to accurately simulate various CFD industrial applications. Learn more about how you can incorporate FLOW-3D products into your design workflow.

Modeling Capabilities

FLOW-3D has an extensive physical and numerical capabilities that have been developed over its 40-year history, such as incompressible free-surface internal and external flow, heat transfer, turbulence, moving and deforming solids, surface tension and phase change.

Case Studies

Explore how FLOW-3D customers use simulations to speed up production, research new materials and processes, and optimize for ideal design solutions.


The FLOW-3D Bibliography contains an extensive collection of technical publications that contain FLOW-3D results.


CFD-101 is designed to give a general introduction and overview of a variety of issues concerning computational fluid dynamics.


Collection of Resources with information about FLOW-3D

CFD Services

For those whose modeling needs exceed even the broad capabilities of FLOW-3D, Flow Science offers expert development services. Flow Science has an extensive history of contracting to explore new approaches and developing unique solutions.


List of our Partners

About Us

Based in Santa Fe, New Mexico USA, Flow Science was founded in 1980 by Dr. C. W. (Tony) Hirt, who was one of the principals in pioneering the “Volume-of-Fluid” or VOF method while working at the Los Alamos National Lab.

Contact Line Insights

FLOW-3D has many numerical modeling capabilities ideal for engineers interested in improving coating performance. Computational simulation is an excellent way to study the relative importance and effect of different physical processes affecting coating flows.


Optimize product designs and reduce time to market with FLOW-3D, a highly-accurate fluid flow simulation software that specializes in solving transient, free-surface problems. FLOW-3D's complete multiphysics suite includes our state-of-the-art postprocessor, FLOW-3D POST.

Academic Program

Flow Science offers free academic license programs for FLOW-3D, FLOW-3D HYDRO and FLOW-3D CAST to faculty members, researchers, instructors, and students at academic institutions in the United States and Canada, as well as in many other countries through our subsidiaries , Flow Science Latin America, Flow Science India, and Flow Science UK. Academics in other regions should contact their FLOW-3D distributor directly for more information on program availability and license options.


Our support staff is comprised of experienced engineers who understand the needs and problems facing our customers in competitive professional environments. We pride ourselves on offering timely, professional support from our expert CFD Engineers for all FLOW-3D products.


Whether you have a short-term project, want to understand how FLOW-3D or FLOW-3D CAST can be applied to a specific area of interest, or want to take your current use of FLOW-3D to the next level with FLOW-3D CLOUD, our team of experienced CFD engineers is ready to show you how we can help with your modeling needs.


FLOW-3D is used around the world by organizations ranging in size from Fortune 500 firms to small, family-owned enterprises, in both R&D and production settings, to tackle the most challenging free surface flow simulations in a wide variety of CFD application areas.

2014 FLOW-3D Americas Users Conference Press Release -- Skipped, No-index

Flow Science Recipient of Best Places to Work in New Mexico Award -- Skipped, No-index

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2013 FLOW-3D World Users Conference Speakers and Poster Authors Announced -- Skipped, No-index

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2013 FLOW-3D World Users Conference Announced -- Skipped, No-index

Flow Science Announces Release of FLOW-3D Version 10.1 -- Skipped, No-index

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