CFD-Driven Laminar Flow Optimization of Ink Refill Geometry

Newell Brands, Chennai, India

January 2021 - March 2021

Product Development engineer

Industrial

A CFD-based analysis was conducted to enhance the performance of an existing free-flow ink delivery system used in printing applications. A detailed numerical model was developed incorporating ink rheological properties (viscosity dependence), temperature effects, inlet pressure conditions, and nozzle geometry to resolve internal flow behavior. The study identified localized turbulence, recirculation zones, and non-uniform velocity profiles contributing to inefficient ink distribution and material wastage. Parametric design iterations were performed within the CFD framework, including nozzle contour refinement, pressure optimization, and flow path smoothing to promote stable laminar characteristics and reduce shear-induced disturbances. The optimized configuration demonstrated improved velocity uniformity, reduced turbulence intensity, and enhanced outlet flow stability, leading to better ink utilization efficiency and improved print consistency while maintaining manufacturability and process constraints.