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

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