[mullenc525]

I'm designing a manifold for a device similar to a heat exchanger consisting of many small channels, about 300-3000 depending on the scale of the device and whether I decide upon a symmetrical design or not.

Currently I am attempting to mesh the channels with sweep then use an unstructured mesh on the manifolds. This is OK but I cannot figure out how to make the mesh connections 1:1. I am importing a solidworks assembly into CFX-mesh so I have separate 3D regions to mesh. I am unsure of which feature will force the mesh to be 1:1 and uncertain whether an assembly is the most appropriate method to import this geometry.

Also, I have a gut feel the design of the inlet side manifold is much more important than the outlet manifold. I'd like to do some work where I model only the manifold, and each channel is a 2-D region where the pressure on that face is a function of the flux through that region. How can I easily set this up for 300-3000 regions?!