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"A small nozzle orifice size results in small droplet sizes." This assumption is often not true, in particular for multiple-fluid or twin-fluid nozzles due to high demanding tolerance and surface finish requirements. Seemingly small manufacturing errors have a big impact on the spray performance of nozzles with a small orifice. Poorly designed and manufactured micro nozzles may therefore perform worse than larger scale nozzles. The presumption for a successful miniaturization and small droplet sizes is consequently the nozzle design and fabrication technique employed. Micro-nozzles should be designed and precision machined to prevent manufacturing errors and improper assembly. For example, the liquid nozzle and the inner contour of the gas cap should be shaped using a special micro-machining procedure to maximize the concentricity and surface finish of the atomizing end. It is important that the concentricity of the gas and liquid orifice is ensured by tight tolerances and the use of..