We here report on three parallelized designs of the new edge-based droplet generation mechanism, which, unlike existing mechanisms, produces many equally sized droplets simultaneously at a single droplet formation unit. Operation of the scaled-out systems is straight forward; only the oil inlet pressure has to be controlled to let all the units produce oil droplets, given certain basic design constraints. For systems with a typical nozzle depth of 1.2 microm, the mean droplet diameter is 7.5 microm and the coefficient of variation is below 10%. The number of droplets that is formed per unit can easily be increased by increasing the length of the unit. The stable pressure range in which monodisperse droplets are formed can be extended by small adjustments to the design. Overall, the EDGE devices are simple in design and robust in use, making them suitable for massive outscaling.

Although many aspects of microchannel emulsification have been covered in literature, one major uncharted area is the effect of viscosity of both phases on droplet size in the stable droplet generation regime. It is expected that for droplet formation to take place, the inflow of the continuous phase should be sufficiently fast compared to the outflow of the liquid that is forming the droplet. The ratio of the viscosities was therefore varied by using a range of continuous and dispersed phases, both experimentally and computationally. At high viscosity ratio (g d /g c ), the droplet size is constant; the inflow of the continuous phase is fast compared to the outflow of the dispersed phase. At lower ratios, the droplet diameter increases, until a viscosity ratio is reached at which droplet formation is no longer possible (the minimal ratio). This was confirmed and elucidated through CFD simulations. The limiting value is shown to be a function of the microchannel design, and this should be adapted to the viscosity of the two fluids that need to be emulsified.

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