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Optimising Flow through Structure and Operation

Thermal Cascade is centred on the principled design of fluid structures, coupling them to objectives of mixing, mass transport, and heat transfer.

Design Areas

This design process has produced a new design and operating conditions for an oscillatory flow reactor (under provisional patent) for manufacturing fine chemicals and pharmaceuticals. Further R&D efforts are focused on heat exchangers and battery technologies.

Check out the flow reactor

Fluid–Solid Coupling

Our high-fidelity simulations allow us to inspect how geometry drives changes in flow structure. An objective, such as heat efficiency (TPF), is then coupled to these designs.

Twisted tape · twist ratio

2 turns
3D structuredrag to rotate
Twisted-tape topology cross-section
Topologycross-section
Twisted-tape velocity cross-section
Velocitysecondary flow
2 turns3 turns5 turns

Twist-ratio sweep. A twisted tape reaches TPF ≈ 2.2 — strong heat transfer, but a heavy pumping penalty.

Schwarz-P (TPMS) · porosity ψ

ψ 0.45 · dense
3D structuredrag to rotate
Schwarz-P topology cross-section
Topologycross-section
Schwarz-P velocity cross-section
Velocityvelocity magnitude
ψ 0.45 dense0.550.650.75 open

Porosity (ψ) sweep. The dense champion reaches TPF ≈ 3.5–4 — matching state-of-the-art additive TPMS exchangers, at a fraction of the tape's drag.

Real CFD on standard geometries. Every surface, cross-section and velocity field here is from our own high-fidelity simulation (Pr ≈ 7, Re ≈ 200, laminar) of a published benchmark geometry — twisted tape and Schwarz-P (~140-year-old prior art). They validate the pipeline; our own design engine and the surfaces it generates are not shown.

Inverse Design

A forward simulation evaluates one shape you already drew. Our engine runs the problem backwards: given a thermal-hydraulic duty, we build the solid topology to improve it.

Input — target spec
  • Objective (e.g. heat, mixing, or mass transport)
  • Build & print constraints
  • Fluid & operating regime
Output — printable geometry A build-ready Schwarz-P heat-transfer structure, 3D cutaway

Joshua Taubman

Founder & Director, Thermal Cascade Pty Ltd — Sydney, Australia

Thermal Cascade was founded out of a series of independent research projects after Joshua returned from his studies in Nuclear Engineering in France.