In this work inside a circular cross-section channel by 800 micron diameter, a 200 micron T-junction is used to generate micro-droplets of water in oil with two different examined liquids as the continuous phases. The effect of relative flow rate and viscosity of the phases have been studied and demonstrated that these parameters affect the shape, size, velocity and separation of the droplets inside the running phase within the channel. Design and fabrication of various 3D microchannels were carried out via a new appliance by a quick process known as micro-wire molding. The advantages of this method are simultaneous curing and molding without any displacement or a curing oven. By this method channels could be designed and fabricated with different cross-sections, shapes and geometries in a one-pot.
