New portable microchannel molding system based on micro-wire molding, droplet formation studies in circular cross-section microchannel

This work describes a new appliance for design and fabrication of various 3D microchannels by a quick process known as micro-wire molding. The method provides several possibilities including simultaneous curing and molding without any displacement or a curing oven. Both metallic and Nylon micro-wires can be used in this method. The method is designed so that the molding container needs minimal polydimethylsiloxane providing possibility to produce channels with different cross-sections, shapes and geometries. Inside a circular cross-section channel by 800 mu m diameter, a 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.