A three-dimensional (3D) geometry model of twin screw expander has been developed in this paper to measure and analyze geometric parameters such as groove volume, suction port area, and leakage area, which can be described as functions of rotation angle of male rotor. Taking the suction loss, leakage loss, and real gas effect into consideration, a thermodynamic model is developed using continuity and energy conservation equation. The developed model is verified by comparing predicted results of power output and internal efficiency with experimental data. Based on the model, the relationship between mass flow rate through inlet port and leakage path with rotation angle of male rotor as well as effects of the inlet parameter and operating parameter on the performance of the expander are analyzed.