In microfluidic systems, droplets undergo intricate deformations as they traverse flow-focusing junctions, posing a challenging task for accurate measurement, especially during short transit times. This study investigates the physical behavior of droplets within dense emulsions in diverse microchannel geometries, specifically focusing on the impact of varying opening angles within the primary channel and injection rates of fluid components. Employing a sophisticated droplet tracking tool based on deep-learning techniques, we analyze multiple frames from flow-focusing experiments to quantitatively characterize droplet deformation in terms of ratio between maximum width and height and propensity to form liquid with hexagonal spatial arrangement. Our findings reveal the existence of an optimal opening angle where shape deformations are minimal and hexagonal arrangement is maximal. Variations of fluid injection rates are also found to affect size and packing fraction of the emulsion in the exit channel. This paper offers insight into deformations, size, and structure of fluid emulsions relative to microchannel geometry and other flow-related parameters captured through machine learning, with potential implications for the design of microchips utilized in cellular transport and tissue engineering applications.
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