Patent ID: 8790561

Claim:
A method for use in fabricating an embosser drum, comprising: making a plurality of replicas of an embossing master, wherein each of the replicas includes a pattern of nanostructure, wherein a width of the embossing master is approximately half an axial width of the embosser drum to be formed, and wherein a length of the embossing master is approximately half of a circumference of the embosser drum to be formed; bonding the plurality of replicas of the embossing master together in a particular orientation to create a bonded replica structure including a surface having a pattern of nanostructures thereon, wherein the pattern of nanostructures on the surface of the bonded replica structure comprises the combination of the patterns of nanostructures of the plurality of replicas of the embossing master; producing a replica of the bonded replica structure; and generating an embossing plate from the replica of the bonded replica structure.