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Phase aberration arises from the speed of sound heterogeneity in the imaging environment and degrades image quality. Accurate aberration simulation is essential for developing aberration correction methods. Existing works often apply an aberration value at each channel in simulation software, but this approach introduces aberration integration error, assumes a fixed profile across all beams, and does not account for harmonic generation. We propose to address these limitations by making a PDMS aberration phantom. The manufacturing process involves (1) integrating a software-generated profile into a 3D-printed mold, (2) treating the mold with acrylic lacquer to prevent cure inhibition, (3) casting the mold with PDMS and degassing for an hour, and (4) baking at 75 °C for 4 h before demolding. The phantom is smooth and retains software-specified root mean square and full width half max of the autocorrelation function, and can be placed at the transducer to simulate aberration with higher fidelity than software. OCT data suggests that 3D-printed molds are accurate to within 21 μm of the software profiles and beamformed aberrated data exhibits a profile-dependent increase in sidelobes relative to clean data.