The optical fiber coating process, using a die and applicator system, was numerically simulated. The coupled partial differential equations, governing the fluid flow and heat transfer, were solved on a transformed, non-uniform, staggered grid. A finite volume method, with conjugate heat transfer, boundary-fitted grid, and variable transport properties, was employed. The pressure was calculated using a SIMPLE-based algorithm. An isothermal case was first modeled, where the effect of the Reynolds number (Re) was studied for different geometries. Different coating fluids were considered. A conjugate boundary condition was employed at the fiber-fluid interface for the non-isothermal flow. A free surface boundary condition was used at the fiber entry into the coating fluid. The meniscus was prescribed on the basis of prior experimental work. Regardless of fiber speed, a circulating flow was observed in the applicator. High shear rates at the dynamic contact point suggest that air can be entrained with a fast moving fiber. It was also found that pressures at the coating fluid inlet did not play a major role, for typical fiber speeds, whereas the thermal conditions that affect the properties of the fluid, such as viscosity, made a significant impact on both the flow and the thermal field. This work could be used to determine the parameters that are critical for improving the quality of the coating, particularly its uniformity, and the production rate. (c) 2006 Elsevier Ltd. All rights reserved.