The efficient study of liquid droplets ranging from micrometers to a few centimeters by levitation is usually hindered by conventional design limitations. This is due to continuous droplet deformation in the test section. This research discusses the development of a robust design methodology for large droplet-stabilization (d > Capillary Number (Ca)) vertical wind tunnels. A modeling and simulation design environment has been developed that involves component sizing and integration at a central ANSYS-Fluent platform, followed by design optimization. The work inculcates numerical analysis of guide vanes to minimize the viscous losses and, subsequently, the wind tunnel dimensions. The process is followed by the design of honeycomb and wire screens and their analyses for a given geometry. A multi-variable design optimization problem has been optimized with response surface approximations. Statistical modeling of the expensive functions obtained from the solution of Navier-stokes equations has been accomplished in order to deal with non-linear and discontinuous behavior. Numerical optimization of the meta-model can help to find the most feasible wind tunnel design with computational efficiency. A non-conventional design with varying test area cross-sections has been introduced to investigate the droplet stability in constantly changing velocity profiles. Longitudinal as well as lateral velocity variations in the test section, creating velocity buckets with minimum turbulence intensity, has been introduced and analyzed using novel concept designs. The research highlights a systematic design methodology and an alternate configuration for liquid droplet wind tunnels while focusing on stable droplet levitation.