The Ins And Outs Of Casting Lenses From Epoxy

Apr 05, 2024

If you need a lens for a project, chances are pretty good that you pick up a catalog or look up an optics vendor online and just order something. Practical, no doubt, but pretty unsporting, especially when it’s possible to cast custom lenses at home using silicone molds and epoxy resins.

Possible, but not exactly easy, as [Zachary Tong] relates. His journey into custom DIY optics began while looking for ways to make copies of existing mirrors using carbon fiber and resin, using the technique of replication molding. While playing with that, he realized that an inexpensive glass or plastic lens could stand in for the precision-machined metal mandrel which is usually used in this technique. Pretty soon he was using silicone rubber to make two-piece, high-quality molds of lenses, good enough to try a few casting shots with epoxy resin. [Zach] ran into a few problems along the way, like proper resin selection, temperature control, mold release agent compatibility, and even dealing with shrinkage in both the mold material and the resin. But he’s had some pretty good results, which he shares in the video below.

[Zach] is clear that this isn’t really a tutorial, but rather a summary of the highs and lows he experienced while he was working on these casting methods. It’s not his first time casting lenses, of course, and we doubt it’ll be his last — something tells us he won’t be able to resist trying this all-liquid lens casting method in his lab.