Patent ID: 7517205

Claim:
An apparatus for forming an optical film comprising: a mold for defining a shape for optical structures in the optical film; a liquid material dispenser, wherein said liquid material dispenser feeds a radiation curable liquid material to the mold; a continuous mask film, for defining a pattern that further defines areas of the optical film where curved portions are to be made in the optical structures therein; a continuous base film dispenser, for feeding a transparent base film between the mask film and the mold; and a radiation source positioned for simultaneously curing and patterning the liquid material by irradiating the liquid material through the overlapping mask film and base film, such that the liquid material is cured to form the optical film, and such that the curved portions as defined by the mask film are patterned in the optical structures at the same time that they are cured, via differential exposure to the radiation in an area of the radiation curable liquid material blocked from the radiation source by the pattern.