Lens Used for Silicone Mold

Rear of each Light Housing

Rounded Panel with 3 Light Cutouts

Round Single Street Cover

Builds In Progress

Street Light

Not sure why, but I wanted to create my own street light. It features LEDs, an Arduino controller with WiFi and notifications, resin-cast lenses from silicon molds, 3D printed parts, as well as some store bought piping.

The Tools

  • 3D printer (Creality CR-10)
  • dremel with saw attachment
  • mini blowtorch
  • hot glue gun

The Materials

  • black and clear PLA filament
  • 2 part silicon mold compound
  • 2 part epoxy resin compound
  • food coloring and epoxy tiny
  • M2 bolts and nuts
  • sandpaper
  • grey filling undercoat rattlecan
  • high temp matte black paint rattlecan

The Design

Designing the initial pieces

I eye-balled the design after staring at pictures of street lights. I noticed that they are different everywhere. Some have fully round covers, others are cut out like I have. Some have small backs, some large. Some are black with yellow outlines, some don’t. The pro is that I just need to design something close, the con is that there’s no single classic design.

The above files were all designed in Solidworks. They are meant to be assembled using M2 bolts/nuts to give it the industrial look. I didn’t design the pole/stand yet because I wanted to get a feel for the size first before deciding on the pole height and thickness.

The Build

Initial print with “transparent” PLA

I was really unhappy with the “transparent” PLA that i used to print the lenses. There were 2 versions I printed in attempting to get it clear. They were a big fail, but I ended up using it to make a silicone mold which I use to cast resin which worked out much better!

Old silicon mold compound was rock hard

Of course my existing silicone compound had expired. I didn’t even know they have expiration dates. You can see it’s nearly full, only used it once for a test. Had to buy compound as these have about a 1 year shelf life, or a few months if you open the bottle.

Making the silicon mold

I used a glue gun and foam board to put together a tiny box for the mold. I also glued the lens the bottom to prevent it from shifting.

Mold poured

The mold takes about 12 hours to cure. There was absolutely no smell, and the compounds were easy to clean, unlike 2 part epoxy resin.

Green resin casted!

I normally color resin with a few drops of food coloring, but usually you can use acrylic paint. I bought some resin coloring just for kicks and the green came out perfect. The red however was way to opaque and I resorted back to food coloring to get a more translucent resin.

Finally looking legit!

Green and yellow came out perfect the first time. Red took me 3 times to get right. I don’t have a degassing chamber so there are tiny bubbles, I think it will help with diffusing the LEDs under. We shall see!

First test with level converter for 3.3v to 5v signalling on the 8212b

ESP8266 is a 3.3v controller. 8212b is a 5v signal. Here I am doing a quick prototype test to see if the signalling works… spoiler alert, it didn’t. Adafruit’s NeoPixel library didn’t like it.

Soldering took forever!

I used 5v neopixels (8212b) to form an array of lights, 10 LEDs for each street light. I mounted card stock under it to help with the color and adhesion.

Debugging digital signals from the 8212b channel

Using 5v Arduino Nano I was able to get good signalling to the 8212b neopixels. However, this needs WiFi so I switched to a beloved ESP8266 3.3V microcontroller. I could not get the signal to work correctly using Adafruit’s NeoPixel library. Instead I had to switch over to FastLED.

Nightmare comparing signals between Nano and ESP8266!

I used my trusty Rigol to try to diagnose the difference between the signal libraries. At the end of the day, I don’t have time to debug the Adafruit library and running with FastLED. Also look how clean the signal is! those series resistors really help with bounce!