Patent ID: 7658877

Claim:
A replication process for manufacturing a plurality of optical elements having a structured surface with structural features, comprising the steps of: a. providing a replication tool having, on a replication surface, negative structural features being a negative of at least some of the optical element structural features, and further having at least one spacer portion protruding from the replication surface, the at least one spacer portion comprising at least a portion arranged between the structural features corresponding to different optical elements, b. providing a substrate comprising a first surface and a material component in a plastically deformable or viscous or liquid state, c. bringing said material component in contact with said replication surface while the spacer portion abuts against the first surface of the substrate while the material component is between the replication tool and the substrate and thus replicating from the replication surface, the plurality of optical elements, d. hardening the material component, and e. removing the replication tool, f. wherein the hardened material component adhering to the first surface of the substrate forms the plurality of optical elements.