This paper describes the fabrication of PDMS microchannels of various configurations including T-junction, cross junction and diamond shape that accomplished using Xurography technique. The experimental characterization of droplets formation within the fabricated microchannels was performed by introducing a continuous phase and dispersed phase. The flow regimes of squeezing and dripping were observed in the microchannels. The Capillary number affects the patterns of flow regimes and the droplet frequencies in the microchannels. The droplet frequency was dependent on the volumetric flow rate of the continuous phase. The droplet frequency increases as the continuous phase flow rate increases. The smaller size of the droplets is formed at the larger Capillary number. © 2018 Elsevier Ltd.