Patent ID: 9415539
Filing Date: 2016-08-16
CPC Classification: B29C,B29D,B29K,B29L,G03F,Y10T

Claim Text:
1. A method of making a molding tool, the method comprising: providing a first molding tool having a first microstructured surface that includes a first plurality of cavities; providing a second molding tool having a second microstructured surface that includes a second plurality of cavities; filling at least one of the first or second pluralities of cavities with a radiation curable resin; contacting the first and second molding tools against the radiation curable resin such that the first and second pluralities of cavities face each other with a layer of the radiation curable resin therebetween and in contact with the first and second pluralities of cavities; exposing the layer of the radiation curable resin to a patterned irradiation through at least one of the first molding tool or the second molding tool to provide a corresponding partially cured resin layer comprising at least one first region and at least one second region, wherein the at least one first region is irradiated by the patterned irradiation and the at least one second region is not irradiated by the patterned irradiation, and wherein at least one of the first molding tool or the second molding tool is transparent to the patterned irradiation; separating the second molding tool from the partially cured resin; and separating the non-irradiated regions of the partially cured resin from the first molding tool, to provide a modified molding tool having a modified microstructured surface that includes a pattern of a matrix of first microstructural features and at least one discontinuous region of second microstructural features, wherein the patterned irradiation comprises at least one of irradiating through transparent regions of a mask, guiding a beam of light, guiding a beam of electrons, or projecting a digital image.