Dataset of CFD simulations, particle trajectories, mesh-independence analyses, experimental validation, and image-processing workflows for inertial droplet separation in spiral microchannels

This data article presents a comprehensive numerical and experimental dataset for investigating inertial droplet separation in spiral microfluidic channels with multiple outlet configurations. The dataset includes three-dimensional COMSOL Multiphysics simulation models, particle trajectory coordinate datasets, mesh-independence analyses, velocity-field distributions, CAD geometries, and experimental validation images obtained from spiral microchannels with 2-5 loops and varying flow-rate ratios. The numerical dataset contains simulation cases corresponding to different channel geometries, flow conditions, and outlet configurations used for optimization of droplet separation performance. Particle trajectory datasets include spatial coordinates of droplets with diameters of 10, 15, 20, and 25 μm extracted at the microchannel outlets. Additional datasets include velocity profiles from different regions of the pinch-flow section, mesh convergence studies with multiple mesh densities, and alternative discretization schemes for selected models.Experimental datasets consist of microfabrication images, microscopy images of separated droplets, and validation experiments performed on fabricated PDMS microfluidic devices. CAD geometries used for numerical simulations and mold fabrication are also provided.These datasets support validation of computational fluid dynamics (CFD) models, benchmarking of inertial microfluidic separation systems, development of data-driven optimization methods, and comparative studies on spiral microchannel-based droplet sorting devices.The repository includes COMSOL simulation models, trajectory datasets, CAD geometries, experimental validation images, MATLAB image-processing workflows, and supplementary numerical datasets associated with the study.