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Low residence time flow reactors (≤100 μs), when combined with photoionization mass spectrometry or matrix isolation/infrared spectroscopy, have the capability to directly probe the elementary pyrolytic reaction mechanism for various fuels. A qualitative analysis of flow inside these reactors (straight tubes approximately 1mm inner diameter and 3cm in length made of SiC) suggests pressure and velocity significantly change along the length of the reactor. This presents a challenge in determining actual flow conditions within the reactor making it complicated to establish conditions at which pyrolytic chemistry occurs. Computational and experimental testing have been used to optimize a new reactor geometry to control the flow profiles by adding a constriction at one end of the reactor. The nozzle has been shown computationally to stabilize fluid flow within the reactor. A review of available manufacturing processes and coating techniques to incorporate this constriction are presented along with the final processes selected. Further computational and experimental evaluations are discussed to highlight the performance of this new nozzle. The novel design of the micro-reactor will assist researchers in carrying out fundamental kinetic measurements of short residence time pyrolytic reactions of fuels influencing the creation of more efficient fuels and in sustainable engine technology.