Dear Pawan,
You may find interesting alternative materials in this review: https://www.elveflow.com/microfluidic-tutorials/microfluidic-reviews-and-tutorials/materials-for-microfluidic-chips-fabrication-a-review-2017/.
If you want to continue working with PDMS, you can have a look here: https://www.elveflow.com/microfluidic-tutorials/microfluidic-reviews-and-tutorials/the-poly-di-methyl-siloxane-pdms-and-microfluidics/, where RTV 615 is presented as an alternative to Sylgard.
I hope it helps!
Noémi
Flexdym is a great alternative to PDMS, which saves you time and money.
The fabrication protocol is easy to use and only 2-15 minutes long, depending on your application. And because Flexdym is a thermoplastic, it can be recycled and re-molded. Check it out at https://eden-microfluidics.com/
I had a similar inquiry. Has anyone tried to get ~100nm features from Sylcap 284-F? It seems to be much cheaper than Sylgard 184...
PMMA is a cheaper solution but PDMS is best if you are looking for quality channels. Sealing is more effective in PDMS.
What size are you channels Pawan Kumar ? If they are >100 microns, have you considered laser-cutting of acrylic (PMMA)? We have published an ultrafast cutting+bonding solution. Sealing is very effective has demonstrated in the article.
Article Safe and cost-effective rapid-prototyping of multilayer PMMA...
This gets you in just 15 min from design to chips. We have a helpful video on Youtube as well : https://www.youtube.com/watch?v=JzdkNnLQzMU
Let me know if you have any questions or if you want additional tips!
Eden Microfluidics has a material called "Flexdym". I replicated micro-features at 100degC and ~1kg load easily. Very easy material to work with and much less messy then PDMS. See below:
https://eden-microfluidics.com/eden-materials/flexdym-pack-alternative-to-pdms/
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