Large scale microdroplet generation apparatus and methods of manufacturing thereof

A microfluidic device, comprising:

• at least one first channel train in fluid communication with and associated with a first inlet, the first inlet being configured to receive a continuous phase fluid,
• at least one second channel train in fluid communication with and associated with a second inlet, the second inlet being configured to receive a dispersed phase fluid;
• at least one product generator configured to produce a product from the continuous phase fluid and the dispersed phase fluid,
• the at least one product generator being in fluid communication with the at least one first channel train and the at least one second channel train,
• the at least one product generator comprising a first channel that receives continuous phase fluid of the first channel train and a second channel that receives dispersed phase fluid of the second channel train, the first channel and the second channel arranged so as to contact the continuous phase fluid and the dispersed phase fluid at a contacting region, and
• the at least one product generator comprising (1) a velocity reduction section upstream of the contacting region and configured to reduce a velocity of at least one of the continuous phase fluid or the dispersed phase fluid as the at least one of the continuous phase fluid or the dispersed phase fluid approaches the contacting region and (2) a flow resistance increasing section upstream of the velocity reduction section such that fluid passing through the first inlet first traverses the flow resistance section and then the velocity reduction section before arriving at the contacting region;
• and
• one or more outlets for delivery of the product,
• one or more of the first inlet, the at least one first channel train, the second inlet, the second channel train, the at least one product generator, and the one or more outlets optionally being formed in a silicon substrate.