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The importance of Carbon dioxide (CO₂) gas detection as a greenhouse and exhale breathe gas is an undeniable issue. This study aims to propose a new miniaturized, low cost and portable no dispersive infrared (NDIR) system for detecting CO₂ gas.

Poly(methyl methacrylate) (PMMA)-based channels with Au coating because of its high reflection properties in IR region were used in this work. The optical windows were fabricated using PDMS polymer which is cost effective and novel in comparison to other conventional methods. The effects of channel dimensions, lengths and entrance angle of light on optical path length and losses were analyzed with four types of channel using both simulation and experimental tests.

The simulation results indicate that the 0 degree light entrance angle is the most efficient angle among different investigated conditions. The experimental data are in agreement with the simulation results regarding the loss and optical path length in different types of channel. The experimental tests were performed for the 0.5% up to 20% of CO₂ concentration under constant temperature and humidity condition. The results show that the device with 5  and 2 cm channels length were saturated in 4% and 8% concentration of CO₂ gas, respectively. Response and recovery times were depending on gas concentration and channels specifications that in average found to be 10 S and 14 S, respectively, for the largest size channel. Moreover, the environment humidity effect on detection system performance was investigated which had no considerable influence. Also, the saturation fraction absorbance value for devices with various dimensions were 0.62 and 0.8, respectively.

According to the performed curve fitting for practical situation and selected CO₂ concentration range for experimental tests, the device is useful for medical and environmental applications.

PMMA with Au deposition layer was used as a basic material for this NDIR system. Besides, a novel PDMS optical window helps to have a low cost device. The effects of channel dimensions, lengths and entrance angle of light on optical path length and losses were analyzed using both simulation and experimental tests. Using narrowband optical filter (100 nm bandwidth) helps to have a system with good CO₂ selectivity. In addition, experimental tests with different channel dimensions and lengths covered a considerable range of CO₂ concentration useful for medical and environmental applications. Finally, curve fitting was adopted for a modified Beer–Lambert law as a practical situation.