Unveiling proportional three‐dimensional scale‐up behavior of a chaotic microreactor and developing mathematical models

Establishing effective scale‐up strategies for chaotic microreactors remains challenging due to complex chaos evolution mechanisms. This study adopts an oscillating feedback microreactor (OFM) as a representative chaotic microreactor, integrates computational fluid dynamics and experimental validation to investigate proportional three‐dimensional scale‐up. We propose a unified analytical framework that bridges flow dynamics (secondary and chaotic structures), chaotic intensity (Lyapunov exponent), and mixing performance through empirical correlations consisting of inertia‐intensification, intrinsic, and scale‐factor terms. Results demonstrate that correlations describe 1×–3× OFMs quantitatively, while 6× and 12× cases retain the inherent feedback‐driven flow and effective mixing despite kinematic prediction deviations. The practical efficacy of this strategy is verified via the continuous synthesis of FePO 4 and Ce 2 (C 2 O 4 ) 3 across various scales, yielding consistent morphologies and comparable LiFePO 4 electrochemical performance. This work establishes a robust methodology and provides guidance for the industrial scale‐up of inertia‐driven chaotic microreactors while retaining effective mixing.