Multiple continuous microfluidic reactors for the scaled up synthesis of gel or polymer particles

A method for producing emulsion droplets, comprising the steps of:

• a) providing a multiple microfluidic reactor for scaled up synthesis in emulsion droplets, comprising:
• i) a first base sheet having a planar top surface;
• ii) a second sheet having relief patterns of a plurality of microfluidic flow-focusing devices, each including an inlet and an outlet, a relief pattern for a first inlet manifold distributor having a fluid inlet and microfluidic flow channels each in communication with the first manifold fluid inlet and the inlets of the plurality of microfluidic flow-focusing devices, the first inlet manifold distributor having a fluid inlet, a relief pattern for an outlet manifold distributor connected to the outlets of the plurality of microfluidic flow-focusing devices, the outlet manifold distributor having a fluid outlet, said relief patterns being formed in a bottom surface of the second sheet, each of said plurality of microfluidic flow-focusing devices having an opening in the top surface of the second sheet in flow communication with an interior of the associated microfluidic flow-focusing device;
• and
• iii) at least a third sheet having a relief pattern of a second inlet manifold distributor in a bottom surface of said third sheet, the relief pattern of the second inlet manifold distributor including a plurality of microfluidic flow channels each in fluid communication with a second manifold fluid inlet and one of said openings in the top surface of the second sheet when said third sheet is assembled on a top surface of the second sheet with the bottom surface in physical contact with the planar top surface in sealing relationship, and wherein assembling the second sheet on the planar top surface of the first base sheet with the bottom surface in physical contact with the planar top surface in sealing relationship forms the plurality of microfluidic flow-focusing devices and the first inlet and outlet manifold distributors;
• and
• b) supplying at least two immiscible liquids, a droplet phase, A, and a continuous phase, B, to the first manifold fluid inlet and to the second manifold fluid inlet respectively, and wherein said two immiscible liquids A and B are forced through a narrow orifice in which a thread of liquid A breaks up and produces emulsion droplets.