A microfluidic device is employed to emulate water droplet emergence from a porous electrode and slug formation in the gas flow channel of a PEM fuel cell. Liquid water emerges from a 50 mu m pore forming a droplet; the droplet grows to span the entire cross-section of a microchannel and transitions into a slug which detaches and is swept downstream. Droplet growth, slug formation, detachment, and motion are analyzed using high-speed video images and pressure-time traces. Slug volume is controlled primarily by channel geometry, interfacial forces, and gravity. As water slugs move downstream, they leave residual micro-droplets that act as nucleation sites for the next droplet-to-slug transition. Residual liquid in the form of micro-droplets results in a significant decrease in slug volume between the very first slug formed in an initially dry channel and the ultimate "steady-state" slug. A physics-based model is presented to predict slug volumes and pressure drops for slug detachment and motion. (C) 2011 Elsevier B.V. All rights reserved.