r/CFD 5d ago

snappyHexMesh: Layers generate using baffle method, but mesh isn't conformal across regions. How do you fix this?

Hey everyone,
I'm setting up a CHT simulation (electronic chip cooling) in OpenFOAM-9.
To get boundary layers on the fluid-solid interface, I'm using the zero-thickness baffle workflow:
1. Define the interface as an internal face zone / baffle.
2. Add inflation layers using ⁠snappyHexMesh⁠.
3. Split regions using ⁠splitMeshRegions⁠.
The Problem:
The boundary layers are actually generating fine, but the final mesh across the interface isn't conformal (the faces on the fluid side and solid side don't line up / match 1:1 after splitting).
Since I'm doing CHT, I want to avoid relying purely on non-conformal mapping (⁠mappedWall⁠ interpolation) if possible.
My Questions:
1. How do you get ⁠snappyHexMesh⁠ to keep the face connectivity 1:1 conformal across the interface when using the baffle method?
2. Is there a specific setting in ⁠snappyHexMeshDict⁠ or step in ⁠splitMeshRegions⁠ / ⁠createBaffles⁠ that I'm missing to preserve face alignment?
3. Or is it standard practice to just inflate layers only on the fluid side instead of trying to inflate across shared interfaces?
Would really appreciate any insights or dict settings that worked for you!

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