I'm working on a few projects that require lenses to focus LED light flashes, similar to those lenses used by police lights (TIR lens) and other strobe traffic lighting utilizing Fresnel lenses. I've scoured the internet and cannot find anyone selling just the lenses or any guides on how they are/can be made in custom situations. I've provided a few examples below:

Link 1

Link 2

I found an article detailing such traffic light lenses and that currently they are chiefly made out of polycarbonate but not anything further.

I am asking how to create these lenses and or trying to find a place that will allow me to purchase them.

  • $\begingroup$ It is fair to say you would like to know how to build these lenses used as described in your question. $\endgroup$ Jul 17 at 10:49
  • $\begingroup$ @MahendraGunawardena Yes, it is fair to say that I am asking either how to build them and or a place to purchase them. $\endgroup$
    – Zero
    Jul 17 at 18:22
  • $\begingroup$ @jsotola I am trying to figure out how to build these lenses. $\endgroup$
    – Zero
    Jul 17 at 18:23
  • $\begingroup$ Those are custom molded items. You would need to be able to design them which will require rather expensive raytracing software and then contact a molder to design and build a mold. Very expense. $\endgroup$
    – Eric S
    Jul 17 at 18:53
  • 1
    $\begingroup$ Making your own from scratch (=not duplicating an existing one) is a heavyweight task. Generating the geometric form which meets the photometric regulations needs real optics engineering knowledge. There really are strict regulations for traffic and warning lights. The needed, say 100nm or better surface smoothness is another thing - especially, if the forms are more complex than a convex looking glass. But check this, if you want to make a copy: youtube.com/watch?v=TN9tHJXXlKs In the video a hobbyist makes an inferior copy of an existing not so high quality very simple lens. $\endgroup$
    – user287001
    Jul 19 at 12:13

Alibaba is the best place to begin sourcing parts. If your quantity is high enough many of the manufacturers can also customize.

Here are a few of the many Alibaba manufacturers:
PMMA (acrylic) lenses
Glass Lenses
Polycarboneate Lenses

The lenses are made by injection molding; the mold is cut (and subsequently polished) out of steel or aluminum by a CNC milling machine. Any optically clear material can be used to form the lens. The above materials are common choices because they are UV resistant for use outdoors in sunlight.


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